Zebra XiII-Series

MaintenanceManual

48452L Rev. 2

Proprietary StatementThis manual contains proprietary information of Zebra Technologies Corporation. It is intended solely for the information and use of parties operating and maintaining the equipment described herein. Such proprietary informationmay not be used, reproduced, or disclosed to any other parties for any other purpose without the expressed writtenpermission of Zebra Technologies Corporation.

Product ImprovementsContinuous improvement of products is a policy of Zebra Technologies Corporation. All specifications and designsare subject to change without notice.

FCC Compliance Statement

Note: This equipment has been tested and found to comply with the limits for a Class A Digital Device, pursuant toPart 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interferencewhen the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radiofrequency energy and, if not installed and used in accordance with the product manuals, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense.In order to insure compliance, this printer must be used with a Shielded Power Cord and Shielded CommunicationCables.The user is cautioned that any changes or modifications not expressly approved by Zebra Technologies Corporation could void the users authority to operate the equipment.

Canadian DOC Compliance Statement

This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus as set outin the radio interference regulations of the Canadian Department of Communications.

Liability DisclaimerZebra Technologies Corporation takes steps to assure that its published Engineering specifications and manuals arecorrect; however, errors do occur. Zebra Technologies Corporation reserves the right to correct any such errors anddisclaims liability resulting therefrom.

No Liability for Consequential Damage

In no event shall Zebra Technologies Corporation or anyone else involved in the creation, production or delivery ofthe accompanying product (including hardware and software) be liable for any damages whatsoever (including, without limitation, loss of business profits, business interruption, loss of business information, or other pecuniary loss)arising out of the use of or the results of use of or inability to use such product, even if Zebra Technologies Corporation has been advised of the possibility of such damages. Because some states do not allow the exclusion or limitation of liability for consequential or incidental damages, the above limitation may not apply to you.

CopyrightsThe copyrights in this manual and the label printer described therein are owned by Zebra Technologies Corporation.All rights are reserved. Unauthorized reproduction of this manual or the software in the label printer may result inimprisonment of up to one year and fines of up to $10,000 (17 U.S.C.506). Copyright violators may be subject tocivil liability.BAR-ONE , SCAN-ONE , TRACK-ONE , Zebra , ZPL , and ZPL II are registered trademarksand WEDGE-ONE, Xi, and XiII are trademarks of Zebra Technologies Corporation.Centronics is a registered trademark of Genicom Corporation.IBM is a registered trademark of IBM Corporation.Windows is a registered trademark of Microsoft Corporation.

DescriptionThe Zebra XiII-Series Thermal Transfer Demand Printers are versatile labeland ticket printers designed to print high quality bar codes, various sizes andstyles of alphanumeric characters, and graphics in either the thermal transfer ordirect thermal mode. The XiII-Series printers have the flexibility to meet a widevariety of applications. The Zebra Programming Language II (ZPL II ) allowsthe programmer to format the printed material. ZPL II is transparent to protocolconverters and allows the XiII-Series printers to be easily integrated with mostsystems and host mainframes.

ScopeThis manual contains the information necessary for the proper maintenance ofthe Zebra 90XiII, the Zebra 140XiII, the Zebra 170XiII, and the Zebra220XiII printers. Information presented applies to all XiII-Series models,unless otherwise indicated.Section 1 (Introduction) provides an overview of the contents of thisMaintenance Manual.Section 2 (The Zebra XiII-Series System) details the printer specifications,communication specifications, and a brief description of the front panel controlsand indicators.Section 3 (Printer Diagnostics) presents the diagnostic tests which are builtinto the XiII-Series printers. Examples of the labels which print for most ofthese diagnostic tests are illustrated.Section 4 (Preventive Maintenance) discusses the recommended cleaningprocedures for the printer and the printhead. Recommended cleaning agents anda preventive maintenance schedule are specified.Section 5 (Corrective Maintenance) provides disassembly, replacement andreassembly instructions for the XiII printers. Required tools and test equipmentare specified. Adjustment procedures are provided along with the requiredtensions, torques and tolerances. Instructions on AC power fuse replacement arealso contained in this section.

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diagnosis and action columns to assist the repair technician in quickly locatingand repairing a printer fault. Example labels illustrate several commonmechanical misalignment conditions and the best methods of adjustment.Section 7 (System Repair) provides in-depth explanations of the operating andtesting features of the XiII-Series printers.Section 8 (Mechanical Drawings and Parts Lists) contains mechanicalassembly drawings and parts lists. Parts and assemblies common to allXiII-Series models are illustrated along with their maintenance part numbers.Those parts that are specific to a particular model are individually identified.Section 9 (Appendices) contains reference material which may assist thetechnician when installing and maintaining the printer.Section 10 is available for the technician to add additional printed materialssuch as installation instructions provided with Option Kits and ReplacementParts Kits.

To ensure that you receive documentation updates, refer to the

registration form at the front of this manual. Complete theregistration form and return it to Zebra Technologies. In this waywe can provide better service directly to the repair technician.

Tear-Off mode: Labels are produced in strips.

Rewind mode:Requires the Media Rewind option. Labels are rewoundinternally onto a 3"-inner-diameter cardboard core.Peel-Off mode: Requires the Media Rewind option. Labels are dispensedand peeled from the liner which is rewound within the printer.Cutter mode:Requires the Cutter option. Media is cut into individuallabels after printing.Applicator mode:Requires the Applicator Interface option. Labels arepeeled from the liner and presented for use by anexternal applicator device.XiII-Series Maintenance Manual

IBM Twinax Interface

IBM Coax Interface

RS-485 Network Interface

Fan Folded Media Supply Bin

SIMM Memory Modules (1, 2, 4, 8 Mbyte)

Applicator Interface

Memory Cards

Media Supply Spindle

Font Cards

KMT printhead (only available

for the 140XiII printer)

Font ROMs

Communication SpecificationsSerial Data Communication Interface OverviewThe Zebra XiII has a single Data Terminal Equipment (DTE) port whichsupports RS-232, RS-422 and RS-485 serial data communications. Baud rate,parity, data length, stop bits, and XON-XOFF or DTR control protocols are frontpanel selectable. Refer to Figure 2-2. A 25-pin DB25S connector at the rear ofthe printer provides the Data and Control Leads necessary to communicatethrough all three signalling methods. The method used is specific to theapplication of the printer.For all RS-232 Data and Control input and output signals, the Zebra XiII followsboth the Electronic Industries Associations (EIA) RS-232 and the ConsultativeCommittee for International Telegraph and Telephone (CCITT) V.24specifications.

Communication BufferThe XiII-Series printer has a communication buffer that stores the incoming datauntil that information can be acted upon (imaged). Communication Handshaking(DTR/DSR control signals or X-ON/X-OFF control codes) isused to control when the host can send data to the printer.The size of the buffer is 5000 characters. As data is received by the XiII-Seriesprinter, the processor monitors the number of characters in the buffer. If thebuffer is filled beyond 4744 characters, the XiII will turn the DTR control leadto the OFF condition (negative voltage) or transmit an X-OFF (DC-3) controlcharacter to the host. When the buffer empties below 4250 characters, the XiIIwill turn DTR to the ON condition (positive voltage) or transmit an X-ON(DC-1) control character to the host.

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Standard Serial Communication Connector

The DTE port is a DB25S connector located at the rear of the XiII-Series printer.It provides connection to a host via RS-232, RS-422 or RS-485 signalling. Referto Figure 2.2 for wiring diagrams.The pinouts and signal descriptions for the DTE port are as follows:Pin 1Frame Ground for cable shield.Pin 2TXD (RS-232 Transmit Data): This lead is the serial data output fromthe XiII-Series printer. It is on this lead that printer status or XON-XOFFinformation is relayed to the host.Pin 3RXD (RS-232 Receive Data): This is the serial data input to theXiII-Series printer from the host.Pin 4RTS (RS-232 Request To Send): This is a control output from the XiIISeries printer to the host. RTS is active (positive voltage) when the printer ispowered ON. An Active RTS indicates that the printer is ready to receive data.Pin 6DSR (RS-232 Data Set Ready): This is a control input to the XiII-Seriesfrom the host. The printer monitors this lead to determine if the host is ready toreceive data/status from the printer.Pin 7Signal Ground for RS-232: This lead serves as the voltage referencebetween the interfaced devices and is DC coupled to Frame Ground inside theprinter.Pin 9+5VDC Source (750mA maximum)Pin 11RS-422/RS-485 Signal Ground ReferencePin 13RS-422/RS-485 Data Input B(-)Pin 14RS-422/RS-485 Data Output B(-)Pin 16RS-422/RS-485 Data Input A(+)Pin 19RS-422/RS-485 Data Output A(+)Pin 20DTR (RS-232 Data Terminal Ready): This lead is a control output fromthe XiII-Series printer to the host. When the DTR control line from the printer isactive (positive voltage), the host is allowed to send data to the printer.When DTR is inactive (negative voltage), the host may not send data to theXiII-Series printer. This condition occurs when the printer is configured forDTR/DSR hardware handshaking and the communication buffer is within 256characters of its capacity.Pins 5, 8, 10, 12, 15, 17-18 and 21-25 are not used and are unterminated.

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Rear Panel Interface Connections

RS-232 Connector (DTE)

Rear Panel DB-25SJ3

+5 V

F1

1 Amp

PARALLELINTERFACECONNECTOR+5 V

F1

Frame Ground

TXD (Transmit Data Output)

RXD (Receive Data Input)

RTS (Request To Send Output)

DSR (Data Set Ready Input)

Signal Ground

+5 VDC Source

20

DTR (Data Terminal Ready Output)

RS-422/RS-485 ConnectorRear Panel DB-25SJ39

+5 VDC Source

14

Output B (-)

19

Output A (+)

13

Input B (-)

16

Input A (+)

11

Signal Ground Ref.

Frame Ground

1 Amp

DB-25 SERIALINTERFACECONNECTOR

+5 V10k20k10k

100

AC POWERON/OFF SWITCH

AC POWERCABLE CONNECTION

Figure 2.2 Interface Connections

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Serial Communication Signal Levels

Refer to Figure 2.3. RS-232 Data Signals are defined as either MARK or SPACEwhile Control Signals are either ON (Active-Positive Voltage) or OFF(Inactive-Negative Voltage). Although the permitted voltage levels can rangefrom 3VDC to 25VDC, the levels for the XiII-Series printer are as follows:RS-232 Transmit and Receive DataMARK or OFF = 7 to 10 VDCSPACE or ON = +7 to +10 VDC

Figure 2.3 RS-232 Signalling

Refer to Figure 2.4. RS-422 and RS-485 Data Signals are also either MARK orSPACE. The voltage levels are +5 VDC and 0 VDC when monitored from aspecified reference point. The levels for the XiII-Series printer, when referencedto Signal Ground are:RS-422 and RS-485 Transmit and Receive DataMARKSPACE

Output/Input A = +5V and Output/Input B = 0V

Output/Input A = 0V and Output/Input B = +5V

Figure 2.4 RS-422/RS485 Signalling

Communication CodeThe XiII-Series printer sends and receives ASCII (American Standard Code forInformation Interchange) characters in either a Serial Data or Parallel Dataformat.NOTE: When using the Serial Data format, the baud rate, number of data and stop bitsper character, and parity are selectable. Parity only applies to data transmitted bythe XiII-Series printer. For received data, the Parity bit is ignored.

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Parallel Data Communications Interface Overview

Refer to Figure 2-2. A standard 36-pin Centronics Parallel Interface Connectoris available at the rear of the printer for connection to a parallel data source.The Parallel Interface receives data from the data source but cannot sendback printer status information over this port. When the Parallel Data Port isused, the standard RS-232 Port will not function as an Input Port. However, ifthe XiII-Series printer receives a Printer Status Request command over theParallel Port, it will send information back over the Standard RS-232 Port.

Parallel Port Connector

The following table shows the pin configuration and function of a standardPC-to-Printer Centronics Parallel cable.Pin No.Parallel Data Port Signal Description1The nStrobe printer input has internal 3.3k ohm pull-up resistors to 5V (IOL= 1.5mA) and isdesigned to receive a signal driven open collector VOL <= 0.8V. This pin is a signal from thehost computer.2-9DATA inputs have TTL input characteristics with internal 3.3k ohm pullups and represent1 TTL unit load or less. The DATA inputs are positive logic with a HIGH voltage levelcorresponding to a logic 1. Pin 2 through Pin 9 = D0 through D7 respectively.10The nAck output is an active LOW pulse indicating that the printer is ready to accept data.The active LOW state precedes BUSY by 7 microseconds. nAck is driven open collectorwith a 3.3k ohm internal pull-up. The output sinks 7 mA to a VOL <= 0.4V.11The Busy output is active HIGH whenever the printer cannot accept data due to conditionssuch as: Buffer Overflow, Head Open, Over Temperature, and Media Error. Busy is drivenopen collector with a 3.3k ohm internal pull-up. The output sinks 7 mA to a VOL <= 0.4V.12The PError signal is active HIGH whenever the printer is out of media or ribbon.13The Select signal function is determined by a configuration option which becomes activewhen the port is selected. In the default condition, Select is active HIGH whenever theparallel port is powered up and the parallel port is enabled. In the non-default condition,Select will go active LOW whenever the printer is printing.14nAutoFd15Not defined16Logic Ground17Frame Ground - is at the same potential as Logic Ground (pin 16).18Fused 5 VDC Supply - 750 mA maximum. (Internal Fuse Protected)19 - 30 SIGNAL GROUNDS are the Logic Grounds and Returns for all Input and Output signals.31 - 35 NOT USED - These leads should be left unconnected.36nSelectIn

Optional Interface Boards

For information about the IBM plug-compatible Twinax Interface, the IBM plug-compatible Coax Interface, the ZebraNet-Ethernet Interface, the RS-485Network Interface, or the Applicator Interface, refer to the instructions whichaccompany the Interface Option Kits.

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Front Panel Controls and Indicators

Front Panel Status IndicatorsThe Status Indicators of the Xi II-Series printer are located on the Front Panel.POWER Status Indicator: Controlled by the Power ON/OFF Switch located atthe rear of the printer. Normally ON to indicate that Primary Power is applied tothe printer. When OFF, indicates Power is removed.TAKE LABEL Status Indicator: (Peel-Off Mode Only) This Indicator isoperative only in the Peel-Off Mode. The Indicator will Flash when a label hasbeen printed and is ready to be removed from the XiII-Series printer. The XiIIwill not print until the label is taken. It may, however, accept label formats if thebuffer is not yet full.When the label is taken, the Indicator will stop flashing and the next label, ifany, will be printed.ERROR Status Indicator: Normally OFF. Flashes ON and OFF when a printererror occurs. Read the Front Panel LCD for diagnostic information.CHECK RIBBON Status Indicator: Normally OFF.Direct Thermal Mode: ON if Ribbon is installed in the printer.Thermal Transfer Mode: ON if Ribbon is not installed or when the end of theribbon has advanced beyond the ribbon sensor. The Indicator turns OFF whenthe printer detects a ribbon in the printhead.PAPER OUT Status Indicator: Normally OFF. ON if Media is not installed or whenthe media has advanced beyond the programmed or learned label length and nolabel edge or marker has been detected.The Indicator turns OFF when the printer detects a media edge or markerAFTER the PAUSE switch is pressed when media is reloaded.PAUSE Status Indicator: Normally OFF.When the PAUSE Key is pressed, the PAUSE Indicator will light and printingwill stop. When the PAUSE Key is pressed again, the PAUSE Indicator turnsOFF and printing resumes.The PAUSE Indicator will light under the following conditions: Pressing the PAUSE Key. Detection of a PAPER OUT condition. A programmed PAUSE is encountered in the label program. Detection of a RIBBON OUT condition. Printhead is opened. If the Printhead is too hot or too cold, PAUSE flashes and the LCDdisplays TEMP OUT RANGE. Printing will resume automaticallywhen the printhead reaches operating temperature.

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The XiII-Series System

DATA Status Indicator: ON indicates that Data Processing or Printing is taking

place, but no data is being received. OFF indicates that no data is being receivedor processed. FLASHING indicates that Data is being received. (Flashing slowsdown when the printer is unable to accept any more data due to the Data InputBuffer being full. Flashing returns to normal rate when the Data Input Buffer isno longer full and data is once again being received.)

Front Panel Keys

The Front Panel Keys shown in Figure 2.3 controlthe various printer operations.PREVIOUS, NEXT/SAVE and SETUP/EXITKeys: See the description under Liquid CrystalDisplay (LCD) on page 2-13.PAUSE Key: Allows the operator to interrupt theprinting of a batch of labels and then complete thebatch by pressing the key a second time.PREVIOUS

NEXT/ SAVE

When this key is pressed, printing will stop after the

label being printed is completed. The PAUSEIndicator will light. Label counter stops but maintainscount balance and holds data in memory.

SETUP/ EXIT

When the key is pressed again, the PAUSE Indicator

goes out and printing is resumed.

POWERTAKE LABEL

FEED Key: In order to prevent accidental loss of

data, this key is ignored unless the printer is notprinting, is between formats, or is first PAUSED(see PAUSE Key above). Pressing this key causesthe media to advance until one of the followingoccurs: The media advances to the start of the next label. A Paper Out condition is encountered.Pressing the FEED Key while turning the power ONcauses a printer Self Test Label to be automaticallyprinted at the end of the Power ON Self Test.

Each subsequent pressing of the CANCEL Key

clears the next batch, if any, from the Print DataBuffer until the Buffer is empty.

CALIBRATE

Pressing the CANCEL Key while turning the power

ON causes the printer Configuration Label to beautomatically printed at the end of the Power ONSelf Test.Figure 2.5 Front Panel ControlsPage 2-12

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The XiII-Series System

CALIBRATE Key: This key is ignored unless the printer is first PAUSED (seePAUSE Key above) in order to prevent accidental loss of data. Pressing this keyonce causes the printer to recalibrate the Media and Ribbon Sensors for properMedia Length, set media type (continuous or non-continuous) and set printermode (direct thermal or thermal transfer).

Liquid Crystal Display and Membrane Keys

The two-line, sixteen-character, liquid crystal display (LCD) and five membranekeys below it are used to program print and communication parameters and todisplay operator messages. The keys and their functions are:BLACK OVAL KEYS: The function of the two black oval keys depends on theparameter being displayed. They are normally used to scroll through multiplesetting choices or increase/decrease variable parameters such as burntemperature.PREVIOUS: Scrolls back to the previous parameter.NEXT/SAVE: Scrolls forward to the next parameter.SETUP/EXIT: Enters and exits the Configuration Mode.

Test routines are built into the Zebra XiII Series Printers to aid the technician indiagnosing faults. Some of these tests are enabled by pressing a front panel keywhile turning the Printer Power Switch ON.

Power On Self Test

A Power ON Self Test (POST) is performed each time the Printer is turned ON.This test checks for proper initialization of various electronic circuits andestablishes starting parameters as those stored in the printers memory. Duringthis test sequence, the front panel LEDs will turn ON and OFF to insure properoperation.At the end of this Self Test, only the POWER LED will remain lit. If other LEDsare also lit, refer to Section 6 (Troubleshooting) in this manual.If the printer is set up for non-continuous media, one or more labels will feedout, up to a maximum length of one label plus three additional inches of media.To initiate the Power On Self Test (POST), turn the Printer ON using the PowerSwitch in the rear. The front panel Power On indicator will light. The other frontpanel LEDs and the Liquid Crystal Display (LCD) monitor the progress andindicate the results of the Self Test. The normal Self Test sequence is shown onthe following page.

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Printer Diagnostics

1.

2.

All LEDs turn ON

simultaneously, then turn OFF insequence starting at the bottomthrough the following steps.SRAM Test

SRAM functionality test

performed.Option ROM functionality test isperformed. (The words NotInstalled will be added to thedisplay if no ROM is used.)

3.

Option ROM Test

4.

Printhead Test

Printhead is checked for proper

operation.

5.

Processor Test

Processor functionality test is

performed. (The word Failedwill be added to the display if thetest does not pass.)

6.

E-Cubed Test

E-Cubed functionality test is

performed. (The word Failedwill be added to the display if thetest does not pass.)

7.

EEPROM Test

EEPROM functionality test is

performed. (The word Failedwill be added to the display if thetest does not pass.)

8.

Memory Card Test

Optional Memory Card

functionality test is performed.(The words Not Installed willbe added to the display if no cardis present.)

9.

10.

The ^MF command causes the

printer to feed to the first web orlabel length, calibrate Ribbon andMedia Sensors, set Label Lengthand feed one or more labels.PRINTER READYx.x MBVx.x.x

Printer Ready For Operation.

Refer to the Configuring to theApplication Section to setspecific parameters.

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When the Power On Self Test is completed, the selected Printer Self Test willautomatically start.NOTE: When performing Self Tests, all Data Interface Cables should be disconnectedfrom the printer.It is recommended that Full Width media be used when performing theseTests. Labels less than full width in size will lose printing on the right side.Label length will determine the amount of printing starting at the top of thelabel.In the Peel-Off mode, the printer does not pause while performing these SelfTests. The Operator must remove the labels as they become available.When Canceling a Self Test prior to its actual completion, always turn theprinter Power OFF and then back ON to reset the printer.

CANCEL Key Self Test

This Self Test prints a single label which contains a listing of the printerscurrent configuration parameters stored in Configuration (EEPROM) Memory.Press the CANCEL key while turning the AC Power Switch ON. See Figure 3.1.The Configuration may be changed either temporarily (for specific label formatsor ribbon and label stock), or permanently (by saving the new parameters inEEPROM Memory.) Saving new parameters occurs whenever a PrinterConfiguration procedure is performed. Refer to the Users Guide for furtherdetails on the Printer Configuration procedure.

Figure 3.1 Cancel Key Test Sample Label

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Printer Diagnostics

PAUSE Key Self Test

This Self Test is actually comprised of four individual test features.1. The initial Self Test prints 15 labels at a speed of 2 per second; thenautomatically PAUSES the printer. Each time the PAUSE key is pressed, anadditional 15 labels will print.2. While the printer is PAUSED, pressing the CANCEL key once alters theSelf Test. Now each time the PAUSE key is pressed the printer prints 15labels at a speed of 6 per second.3. While the printer is PAUSED, pressing the CANCEL key a second timealters the Self Test again. Now each time the PAUSE key is pressed theprinter prints 50 labels at a speed of 2" per second.4. While the printer is PAUSED, pressing the CANCEL key again alters theSelf Test a third time. Now each time the PAUSE key is pressed, the printerprints 50 labels at a speed of 6" per second.5. While the printer is PAUSED, pressing the CANCEL key again alters theSelf Test a fourth time. Now each time the PAUSE key is pressed, theprinter prints 15 labels at the printers fastest speed. (8" per second for the90XiII and 170XiII - 10" per second for the 220XiII - 12" per second for the140XiII.)This Self Test can be used to provide the Test Labels required when makingadjustments to the Printers Mechanical Assemblies. See the label example inFigure 3.2.

Figure 3.2 Pause Key Test Sample Label

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Printer Diagnostics

FEED Key Self Test

NOTE: The CANCEL Key Self Test should be performed prior to this Self Test.Information on the printed Configuration Label (CANCEL key Self Test) willbe used with the results of this Self Test to determine the best Darkness Settingfor a specific Media/Ribbon combination.The FEED Key Self Test Label will print out at various PLUS or MINUSDarkness settings relative to the Darkness value shown on the ConfigurationLabel. Inspect these labels and determine which one has the best darknesssetting for the application. This value can be entered into the printer byconfiguring the Setting Darkness parameter found in Configuration Sectionof the User Guide. See the label example in Figure 3.3 below.The value printed on the selected test label is added to (plus) or subtracted from(minus) the Darkness value specified on the Configuration Label.The resulting numeric value (0 to 30) is the best darkness value for that specificMedia/Ribbon combination and should be entered as the Darkness parameter.

Figure 3.3 Feed Key Test Sample Label

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Printer Diagnostics

Communications Diagnostics Test

This test is controlled by configuring the Setting Communications Modeparameter found in the Configuration Section of the printers users guide.Refer to Figure 3.4 for a sample label resulting from this test.

NOTE: This label will be inverted when printed.

Figure 3.4 Results of Communications Diagnostic Test

FEED Key and PAUSE Key

To temporarily reset the Printer Configuration to the Factory Default values,press these two keys at the same time, while turning the Power ON. The FactoryDefault values will be active until power is turned OFF. If Factory Defaultvalues are Saved during configuration, a Media Calibration proceduremust be performed and some parameters must be reconfigured. Refer to theprinters users guide for more details.Table 3.1 indicates which printer function controls each of the configurationparameters.

Controlled ByConfiguration or ZPL IIConfiguration or ZPL IIConfiguration or ZPL IIConfiguration or ZPL IIConfiguration or ZPL IIConfiguration or ZPL IIConfiguration or ZPL IICalibrate key, configuration or ZPL IIConfiguration or ZPL IIConfigurationConfigurationConfigurationConfigurationConfigurationConfigurationConfigurationConfiguration or ZPL IIConfiguration or ZPL IIConfiguration or ZPL IIConfiguration or ZPL IIConfiguration or ZPL IIConfiguration or ZPL IIConfiguration or ZPL IIConfiguration or ZPL IIConfiguration or ZPL IIConfiguration or ZPL IIConfiguration or ZPL IIConfiguration or ZPL IIConfiguration or ZPL IIConfiguration or ZPL IIConfiguration or ZPL IIConfiguration or ZPL IIConfiguration or ZPL IIConfiguration or ZPL IIConfiguration or ZPL IIConfiguration or ZPL IIConfiguration or ZPL IIConfiguration or ZPL IIConfigurationConfiguration or ZPL IIConfiguration or ZPL IIConfiguration or ZPL II

Table 3.1 Configuration Parameter Controls (con't)

PAUSE Key and CANCEL Key Self Test

This self test can be used to verify proper printer operation after parts have beenreplaced or adjusted. When activated, the printer prints a maximum of 500 HeadTest Labels. Each label backfeeds prior to printing and feeds forward to the restposition after printing. A serialized number will print on each label. Press thePAUSE key or turn the printer power OFF to stop printing. See Figure 3.5 for asample label.

Figure 3.5 PAUSE Key and CANCEL Key Self Test Label

FEED Key and CANCEL Key

This self test is normally performed during the manufacturing process or after amajor overhaul of the mechanical assemblies. This test prints sevenpre-programmed label formats, first at a speed of 6 per second, then the sameformats at a speed of 2 per second. The printer will automatically PAUSE aftereach format. The sequence of label formats is shown in Table 3.2. Refer toFigures 3.7 through 3.13 for sample labels.Page 3-8

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FORMAT

PRINTING

TEST FUNCTION

20 at 6" per second

Left Ribbon Wrinkle Test

20 at 6" per second

Right Ribbon Wrinkle Test

20 at 6" per second

Bar Code Wrinkle Test (Code-39)

20 at 2" per second

Left Ribbon Wrinkle Test

20 at 2" per second

Right Ribbon Wrinkle Test

20 at 2" per second

Bar Code Wrinkle Test (Code-39)

10 at 6" per second

Useable Area Test

10 at 6" per second

Head Temperature Test

10 at 6" per second

Upper Smear Test

10

10 at 6" per second

Lower Smear Test

11

10 at 2" per second

Useable Area Test

12

10 at 2" per second

Head Temperature Test

13

10 at 2" per second

Upper Smear Test

14

10 at 2" per second

Lower Smear Test

Table 3.2 FEED Key and CANCEL Key Label Formats

Extended Printer Diagnostics

Additional Diagnostic Tests are available for Printhead Assembly Adjustments.These Diagnostic Tests are only accessible when the Data Interface Cable isdisconnected from the printer and a Loopback Connector is attached in its place.The Serial Loopback Connector is a 25-pin D Type (DB25P- Male) style withthe following pins tied together. pins 2 and 3 pins 6 and 20 pins 13 and 14 pins 16 and 19The Parallel Loopback Connector is a standard 36-pin parallel connectormounted to a small Circuit Board. This connector is available from ZebraTechnologies as Part # 44680.For each of these Diagnostic Tests, the printer will Transmit the Test LabelFormat out of the Data Interface Connector to the Loopback Connector. TheLoopback Connector passes the Test Label Format back to the printer as ReceiveData and the Test Label is printed.

PAUSE Key Loopback Test

This test demonstrates the media movement capabilities of the printer andprovides a test label to view while making print quality adjustments.With the Loopback Connector in place, press the PAUSE key while turning theAC Power Switch ON.

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Printer Diagnostics

After the Power On Self Test, the printer will print 500 Head Test labels. Eachlabel will backfeed prior to printing and feed to the rest position after printing.A serialized number will print on each label for label comparison purposes ifrequired. See the label example in Figure 3.6 below.The PAUSE key can be used to stop and restart the printing operation.

Figure 3.6 PAUSE Key Loopback Test Label

FEED Key Loopback Test

With the Loopback Connector in place, press the FEED key while turning theAC Power Switch ON.After the POST, the printer will begin printing the same series of label formatsas shown in Table 3.2 for the FEED Key/CANCEL Key test. The printer willPAUSE at the end of each printed format. Press the PAUSE key to begin printingthe next format. Refer to the label examples in Figures 3.7 through 3.13.The PAUSE Key can be used to stop and restart the printing operation. When theprinter is paused, the CANCEL key can be used to move to the next label format.

Maintenance ConceptsMaintenance for the Zebra XiII Thermal Transfer Demand Printer can be dividedinto two basic categories.

This section of the manual contains Preventive Maintenance procedures and

Operator Care instructions. These procedures may be performed by theoperator as well as the Service Technician and should be performed on aregular basis. Preventive Maintenance consists of a visual inspection andgeneral cleaning of the interior and exterior of the printer. PreventiveMaintenance also includes cleaning the printhead and the associated mediaand ribbon paths.

Corrective Maintenance provides the Service Technician with detailed steps

for resolving faults by adjustment or the replacement of components ormodules. The next section (Section 5) of this manual provides detailedCorrective Maintenance procedures.

XiII-Series Maintenance Manual

Cleaning The Zebra XiII Printer

CAUTIONUse only the cleaning agents described in the followingprocedures. Zebra Technologies will not be responsiblefor any other fluids being used on this printer.

EXTERIOR - The exterior surfaces of the XiII-Series printer may be cleaned as

required by using a lint-free cloth. DO NOT use solvents or harsh cleaningagents. If the unit is excessively dirty, a mild detergent solution or desktopcleaner may be used sparingly .INTERIOR - As required, remove any dirt/lint accumulated in the interior of theprinter using a soft bristle brush and/or vacuum cleaner. It is a good practice toinspect these areas after every fourth roll of media.

WARNINGThe use of certain lubricants such as Penetrating Oil andSilicone Oil will damage the printers spindles and inhibitproper operation. DO NOT LUBRICATE any parts in thisprinter unless called for in the installation and adjustmentprocedures.

Cleaning The Printhead

Inconsistent print quality such as voids in the bar codes or graphics may indicatea dirty printhead. For optimum performance, the printhead should be cleanedregularly. Zebra Technologies Corporation recommends performing the cleaningprocedure when installing a new Roll of Ribbon, when installing a new Roll ofDirect Thermal Media or after having printed 500 feet of Continuous or FanfoldMedia.

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It is not necessary to turn the Printer Power OFF prior to cleaning. If Poweris turned OFF, all label formats, images and parameter settings stored in theprinters formatting RAM Memory will be lost. Permanent parameter settingsstored in EEPROM will be retained. When Power is turned back ON, it may benecessary to reload some items into the printers memory.

Printhead Cleaning Procedure:

1.2.3.

4.5.6.

Open the Printhead by moving the Printhead Lever to the OPEN position.Remove the media and ribbon (if present).Refer to Figure 4.1. Use a cleaning swab and wipe the print elements fromend to end. (The print elements are the grayish/black strip just behind thechrome strip on the underside of the printhead.) Allow a few seconds for thesolvent to evaporate.Rotate the Platen Roller and clean thoroughly with a cleaning swab.Brush or vacuum any accumulated paper lint and dust away from the Rollersand the Media and Ribbon Sensors.Reload ribbon and/or media, close and latch the Printhead, restore power(if necessary) and run the PAUSE Key self test to check print quality.

PRINTHEAD

BLACKMARKSENSOR

RIBBONSENSORLABELAVAILABLESENSORS

PLATEN PEEL/TEARROLLERBARFigure 4.1 Cleaning a Typical Printhead

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Cleaning the Upper Media Guide Plate

In the event of a label jam, the Upper Media Guide Plate (Snap Plate) can beremoved and cleaned following these steps.1.2.3.4.5.

To open the printhead to its fully open position, rotate the levercounterclockwise. The printhead pivots to almost vertical.From the front of the printer, pop up the front edge of the Snap Plate usingyour fingernail or a flat-blade screwdriver.Lift the front edge of the Snap Plate while pulling it up and out of themechanism.Clean the Snap Plate. Remove any stuck-on labels and remove all adhesiveresidue using the using swabs soaked in cleaning solvent (alcohol).Replace the Snap Plate by placing the back legs in the openings in the MainMedia Guide while sliding it to the rear of the openings and snapping itdown into position. Refer to Figure 4.2 below.

NOTE: Incorrect installation may disable the Ribbon Sensor or contribute to

print quality problems.

SNAPPLATE

Figure 4.2 Typical Upper Media Guide Plate (Snap Plate)

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Recommended Preventive Maintenance Schedule

AREA

METHOD

PRINTHEAD

Solvent

INTERVALAfter every roll of Media(or 500 feet of Fanfold

PLATEN ROLLER

Solvent

Media) when printing in

Direct Thermal Mode andafter every Roll of Ribbon

TRANSMISSIVEMEDIA SENSOR

Air Blow

REFLECTIVE (BLACKMARK) SENSOR

Solvent

MEDIA PATH

Solvent

LABEL AVAILABLESENSOR

Air Blow

RIBBON SENSOR

Air BlowVisualInspection

Once Per 3 Months

RIBBON FEEDING

Visual Inspection(look for belt wear)

6 Months/500 Rolls

BELTS

when printing in the

Thermal Transfer Mode

Once Per Six Months

Once Per Six Months

MEDIA SUPPLYSPINDLE

Formal Preventive Maintenance is not required.

RIBBON SUPPLYSPINDLE

The Spindle Torques should be tested every

year, or 500 rolls of Media for the Media Take-upand optional Media Supply Spindles orevery 200 rolls of Ribbon for the RibbonSupply and Ribbon Take-up Spindles.

RIBBON TAKE-UPSPINDLE

The Spindle Torques need not be readjusted

unless the printer is malfunctioning.

MEDIA TAKE-UPSPINDLE

Clean stationary cutter blade with solvent when it becomes

gummed up with label adhesive and cut debris.CUTTER OPTIONAfter cleaning, apply a small amountof grease to the moving cutter parts.

Corrective Maintenance Functions

When a problem is encountered with the Zebra XiII Printer, the ServiceTechnician should first insure the unit is being used properly, then exercise it tolocalize the fault. Once localized, refer to the appropriate replacement oradjustment procedure to correct the fault.48452L Rev. 2

Optional Cutter Module

The Cutter Module should NOT be disassembled, but replaced as a unit. Anydisassembly of the Cutter Module voids the warranty.

ConfigurationAfter you have installed the media and ribbon and the POST (Power-On SelfTest) is complete, the front panel display shows PRINTER READY. You maynow set printer parameters for your application using the front panel display andthe five keys directly below it.Refer to the Zebra XiII Printer Users Guide for further details on configuringthe printer for your application.If it becomes necessary to restore the initial printer defaults, see the Feed Keyand Pause Key Self Test in the Printer Diagnostics section of this manual.

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Entering the Program Mode

To enter the programming mode, press the Setup/Exit key. Press either theNext/Save key or Previous key to scroll to the parameter you wish to set.Throughout this process, press the Next/Save key to continue to the nextparameter, or press the Previous key to go back to the previous parameterin the sequence.

Changing Password-Protected Parameters

Certain parameters are password-protected by factory default.CAUTION: Do not change password-protected parametersunless youre sure you know what youre doing! If they areset incorrectly, these parameters could cause the printer tofunction in an unpredictable way.

The first attempt to change one of these parameters (pressing one of the blackoval keys) will require you to enter a four-digit password. This is done via theENTER PASSWORD display. The left black oval key changes the selecteddigit position. The right black oval key increases the selected digit value. Afterentering the password, press the Next/Save key. The parameter you are trying tochange will be displayed. If the password was entered correctly, you can nowchange the value.The default password value is 1234. The password can be changed using the ^KP(Define Password) ZPL II instruction.NOTE: Once the password has been correctly entered, it need not be entered againunless you leave and re-enter the programming mode using the Setup/Exit key.NOTE: You can disable the password protection feature so that it no longer prompts youfor a password by setting the password to via the ^KP ZPL/ZPL IIcommand. To re-enable the password-protection feature, send the ZPL/ZPL IIcommand ^KPx, where x can be any number, 1-4 digits in length, except .

Leaving the Program Mode

You can leave the Program Mode at any time by pressing the Setup/Exit key. TheSAVE CHANGES display will appear. There are five choices, described below.Press the left or right black oval key to display the sequence of choices. Whenyour choice is displayed on the LCD, press the Next/Save key to save settings.PERMANENT - saves the current settings. Values are stored in the printer evenwhen power is turned OFF.TEMPORARY - saves the current settings until changed again or until power isturned OFF.CANCEL - cancels all setting changes made since entering the programmingmode except the Darkness and Tear-Off settings (if they were changed).LOAD DEFAULTS - loads factory defaults settings. Refer to the users guidefor default values.NOTE: If you load factory defaults serttings, you will have to perform a Media andRibbon Sensor Calibration and reset the Head Resistor value before operatingthe printer.LOAD LAST SAVE - reloads the settings made during the last Permanent Save.48452L Rev. 2

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CalibrationThere are two different types of calibration that can be performed by the printer:1) Standard Calibration - pressing the Calibrate key causes the printer to feedmedia and ribbon and set the values it detects for media, media backing material(the spaces between labels), media out, and ribbon in/out status (which determines the print modeThermal Direct or Thermal Transfer). This form ofcalibration also occurs as part of the Sensor Profile and Media and RibbonCalibrate procedures described below.2) Media and Ribbon Sensor Sensitivity Calibration (using non-continuousmedia!) - Performing the Media and Ribbon Calibrate procedure below firstresets the sensitivity of the sensors to better detect the media and ribbon you areusing. With the sensors at their new sensitivity levels, the printer then performsthe standard calibration described above. Changing the type of ribbon and/ormedia may require this calibration process to reset the sensitivity of the Mediaand Ribbon Sensors. Indications that the sensitivity may need to be reset wouldbe a Check Ribbon light ON with the ribbon properly installed ornon-continuous media being treated as continuous media.

Media and Ribbon Sensor Sensitivity Calibration

NOTE: Before you begin this procedure, make sure that the Maximum Length isset to a value equal to or greater than the length of the labels you are using.If the Maximum Length is set to a lower value, the calibration process willassume that continuous media is in the printer.Sensor Profile

1. Press the Setup/Exit key to enter the programming mode.

2. Press the Next/Save key multiple times until the printers LCD displaysSENSOR PROFILE3. Press the right oval key to initiate the standard calibration procedure andprint a Media Sensor Profile.See Figure 5.1 for a media and ribbon sensor profile sample printout.The Media Sensor Profile may be used to troubleshoot registration problemsthat may be caused when the Media Sensor detects preprinted areas on themedia or experiences difficulty in determining web location. If the Mediaand/or Ribbon Sensors sensitivity needs to be adjusted, press the Next/Savekey to access the Media and Ribbon Calibrate procedure below.Media and Ribbon Calibrate

NOTE: The following procedure is used to adjust the sensitivity of the Media andRibbon Sensors. It must be followed exactly as presented. All steps must beperformed even if only one of the sensors requires adjustment.1. Press the Next/Save key to skip this procedure and go to the Setting Host Portfunction, orPress the right oval key to start the calibration procedure. The front panelLCD should showLOAD BACKINGCANCEL CONTINUEPage 5-4

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2. Press the left oval key to cancel the operation, or

Open the Printhead and remove as many labels as needed to load a section ofblank backing material under the Media Sensor. (If you are unsure of theMedia Sensor location, refer to Figure 5.6.)3. Press the right oval key to continue. The front panel LCD should showREMOVE RIBBONCANCEL CONTINUE4. Press the left oval key to cancel the operation orRemove the ribbon (sliding it as far to the right as possible will have thesame effect as removing it), and close the Printhead.5. Press the right oval key to continue. The front panel LCD should showCALIBRATINGPLEASE WAITThe printer automatically adjusts the base settings as determined by the mediaand ribbon sensors due to the specific media and ribbon combination you areusing. On the sensor profile, this essentially corresponds to moving the graph upor down to optimize the readings for your application.When this part of the calibration process is completed, the front panel LCDshould showRELOAD ALLCONTINUE6. Open the Printhead and pull the media forward until a label is positionedunder the Media Sensor.7. Move the ribbon back to its proper position.8. Close the Printhead.9. Press the right oval key to continue. The printer performs the second part ofthe calibration process and the front panel LCD showsMEDIA AND RIBBONCALIBRATEThis part of the calibration is equivalent to pressing the Calibrate key on theprinters front panel. The media sensor determines a new value based on thepresence of media and backing and determines the label length. The ribbonsensor determines a new value based on the presence of ribbon puts the printerin thermal direct or thermal transfer print mode.Once media stops feeding from the printer, the calibration process is complete!10. To see the new settings, press PREVIOUS and print a Sensor Profile.11. Press the Setup/Exit key to leave the programming mode. When asked toSAVE CHANGES, select Permanent.

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Sensor SensitivityThe detailed information which follows amplifies the Media and Ribbon SensorCalibration description and procedure just performed. The procedure prompts the user to load just the liner (backing material) inthe media sensor path and remove the ribbon from the ribbon sensor area.This step prepares the printer to automatically adjust the gain of the mediaamplifier to produce a 3 volt output while sensing just the label liner.This step also prepares the printer to adjust the gain of the ribbon amplifierto produce a 2 volt output while no ribbon is in the path of the ribbon sensor.

Sensing Typical Thermal Transfer Non-Continuous Diecut Labels.

Once the user has loaded backing and removed the ribbon, continuing theprocess adjusts the gain of the sensor amplifiers. The end results of this processare subsequently indicated on the Printer Configuration Label as:Media LED.....Duty cycle applied to the media amplifier to achieve the3 volt output while viewing backing material only.Ribbon LED ...Duty cycle applied to the ribbon amplifier to achieve the2 volt output while viewing only the reflector (ribbon out condition).Reinstalling the ribbon and media and continuing the process (media is feeding)automatically adjusts the remaining values needed to function properly. Thesevalues are determined as follows:The Max Label Length setting is read and the printer begins feeding labels todetermine the Web Sensor value. This value is indicated on the PrinterConfiguration Label as:Web Sensor... the voltage level distinguishing backing only from label plusbacking, specified as a percentage of 5 volts.Media Sensor...the Paper Out value equal to a certain percentage of 5 volts. Thisis programmed to be at 75% (5 volts x 75% = 3.75 volts).The Ribbon Sensor value is calculated. This value is indicated on the PrinterConfiguration Label as:Ribbon Sensor ... determined by taking 75% of the minimum ribbon incalculation. This is displayed as a percentage of 5 volts.The Label Length is now measured by feeding one label. This value is indicatedon the Printer Configuration Label as:Label Length....the distance (in dot rows) between the rising edge ofconsecutive peaks (as it crosses the web value) minus 2 millimeters.

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Media Sensor Profile

The Media Sensor Profile is a graphical representation of the calculated sensorvalues. The limitations associated with successfully printing the profile are thatthe label stock must be wide enough and long enough to allow the whole displayto be viewed. An incorrect label length may inadvertently allow the peaks toprint in the interlabel gap.The following profile represents these sensor values for a typical 1-1/2 6Alabel stock with 5319 Ribbon used in a 140XiII.

Figure 5.1 Typical Media Sensor Profile

NOTE: A Paper Out condition will occur during normal printing functions, if the sensedlevel is above 75% (3.75 volts) for 1/2 of media movement. However, if thesensed value is above 75%, after recovering from an error condition (i.e. HeadOpen, Paper Out, Ribbon Out), the printer will indicate PAPER OUTimmediately. Thus there is no attempt to feed a label any distance until thesensed value is below the Media Sensor value.

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Sensing Continuous Media

Continuous media does not present a web to the Media Sensors. Whenmonitored, the Web Sensor value will be greater than the Media Sensor value.The printer then automatically reconfigures the Media Type to Continuous.

Sensing Tag Stock with a Notch

The Media Sensors can be calibrated using no backing, however this may allowone label length to feed during a paper out condition as if a label were missingfrom the liner. This may occur if the adjusted level of the Media LED allows ano backing condition to achieve 3 volts. A better method of calibration is to usea strip of standard label liner to adjust the sensor sensitivity. The only drawbackto this method is that a Paper Out condition will result if the hole or notch ispresent at the Media Sensor (Web Value exceeds the Media Sensor Value) afteran error condition. See the previous NOTE regarding a Paper Out condition.

Direct Thermal Printing

During the Ribbon LED adjustment, if there is no ribbon in the printer, nodifference in the Ribbon In and Ribbon Out values is detected. Duringdirect thermal printing, the printer continues to monitor the Ribbon Sensor inputand will generate a Ribbon In error and stop printing if the Ribbon Sensorvalue increases during the printing process.

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Standard KST Printhead Replacement

Refer to Figure 5.32 while performing the following procedure.CAUTIONThe printer electronics are susceptible to static discharge. TheTechnician must wear an anti-static wrist strap connected to theprinter chassis when removing and replacing the Printhead.1.2.3.4.5.

Turn the printer OFF and remove the Power Cord.

Open the Printhead Assembly and remove the media and ribbon; then closethe Printhead Assembly.Properly connect yourself to an anti-static protection system.Locate the Spring-loaded Printhead Mounting Screw on top of the PrintheadAssembly.Loosen the Mounting Screw until it disengages from the Printhead.CAUTIONUse care to minimize any physical damage to thePrinthead during the remainder of this procedure.

6.7.8.9.10.11.12.

13.14.

15.16.17.18.19.20.48452L Rev. 2

Slowly open the Printhead Assembly. The Printhead will be resting on thePlaten while the rest of the Assembly pivots back out of the way.Spread apart the holding tabs on the sides of the Printhead Data Connectorsto release the Data Cables.Grasp the outside edges of the Printhead Power Cable Connector and pressdown on the Power Cable Locking Tab.While maintaining pressure on the locking tab, disconnect the PrintheadPower Cable and remove the Printhead through the front of the printer.Prior to installing the new Printhead, note the Resistance Value locatedon the right side of the new Printhead Label.Connect the Printhead Power Cable to the appropriate connector.Spread apart the holding tab on the top of the two data connectors and pressthe appropriate Printhead Data Cable into each connector. The Holding Tabsmust snap into place around the cable connectors.Carefully position the alignment slots in the new Printhead over thealignment posts on the underside of the mounting bracket.Once the Printhead is seated properly, carefully tighten the mounting screw to avalue of 5-6 inch/pounds. (If any problems occur during this installation, contactyour distributor or Zebra Technologies Corporation for technical support.)Refer to Figure 4.1. Use a cleaning swab to thoroughly clean the print element(gray area) of the new Printhead.Reinstall media and ribbon.Connect the AC Power Cord and turn the printer power ON.After the POST, enter the Configuration Mode, enter the new PrintheadResistance value, then permanently save the configuration.Turn the printer OFF, then activate the PAUSE Key Self Test and checkprint quality.The printer should be ready for operation. If problems arise, refer to theTroubleshooting Section.XiII-Series Maintenance Manual

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Corrective Maintenance

DO NOT LOOSENTHESE SCREWS !!PRINTHEADMECHANISMASSEMBLYPRINTHEADMOUNTINGSCREW

Prior to performing Printhead Adjustments

1. Position the toggle(s) as follows:(90XiII) Position the Toggle in the center of the upper printmechanism.

30mm(1163 ")

(140XiII, 170XiII and220XiII) Reference the Printhead

Mounting Screw as the center of two halves of the printmechanism, and position each toggle at the center of each half.2. Compress the Toggle spring by turning the lower knurled nutclockwise until the distance from the top of the toggle foot tothe bottom of the lower knurled nut equals 30mm (1 and 3/16").3. Activate the PAUSE Key Self Test by pressing the PAUSE Keywhile turning the printer power ON.

NOTE: The order in which the adjustments are performed depends on the print qualityof the labels printed during the PAUSE Test above.The first two Printhead Adjustments (Parallelism and Wear Plate) must becompleted prior to attempting to locate the optimum print position. As with theother adjustments, Parallelism and Wear Plate adjustments are interrelated.Adjusting one may have an effect on the position of the other.Excessive toggle pressure will lead to increased Printhead wear anddecreased Printhead life.Increased Printhead life is possible by combining minimum togglepressure and optimum Printhead position over the Platen Roller.

Printhead Parallelism Adjustment

This adjustment is performed in conjunction with the Wear Plate Position,Printhead Position, and Printhead Pressure Adjustments.Adjusting the Printhead Parallelism squares the Printhead in reference to the media.Refer to Figure 5.4 for location of adjustment screws used in the followingprocedure.48452L Rev. 2

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Printhead Parallelism Test

1.2.

3.4.

Prior to starting this test, insure the installed media is squared with theTear-Off Bar.When the printer begins printing PAUSE Key Self Test labels, refer to theusers guide and adjust the Darkness for a clear presentation of all lines onthe test label.The uppermost line on the test label should be parallel to the top edge of thelabel within a tolerance of 0.020.If the print lines are not parallel with the top of the label, proceed to thePrinthead Parallelism Adjustment. If parallelism is within tolerance,proceed to the Wear Plate Position Adjustment.

Printhead Parallelism Adjustment

Refer to Figure 5.4 during this procedure.

1. Using a 7/64" Allen wrench or 7/64" Hex driver, loosen the four Allenscrews at the top rear of the Print Mechanism.2. Adjust the parallel location of the uppermost lines by turning one of the twoflat head screws located at the back of the Print Mechanism.

3.4.5.6.7.

NOTE: Only small adjustments should be required.

To move the Printhead forward, turn the adjustment screw clockwise asviewed from the rear of the printer.To move the Printhead backward, turn the adjustment screwcounterclockwise as viewed from the rear of the printer.Adjust each side as necessary to align the uppermost line of the test label inparallel with the top edge of the label.To check the results of your adjustments, run additional PAUSE Key SelfTest labels and check for proper parallelism.Tighten the four top Allen screws and run more PAUSE Key Self Test labelsto verify proper positioning.TOGGLE KNURLEDADJUSTING NUT

NOTE: LOOSEN 4 HEX CAP SCREWS

BEFORE ADJUSTING HEAD

WEAR PLATEADJUSTMENTSCREWSPARALLELISMADJUSTMENTSCREWS

STRIPPLATE

NOTE: THE RIBBON TAKE-UP SPINDLE

IS NOT SHOWN IN THIS ILLUSTRATION

Figure 5.3 Printhead Adjustment Illustration

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Wear Plate Position Adjustment

This adjustment is performed in conjunction with the Printhead Parallism,Printhead Position and Printhead Pressure Adjustments.Adjusting the Wear Plate position produces even pressure across the full widthof the printhead and platen roller.Refer to Figure 5.3 for the location of the adjustment screws used in thefollowing procedure.1.2.3.4.5.6.7.8.9.

10.11.12.13.

48452L Rev. 2

Using a # 1 Phillips screwdriver, loosen the 2 screws on the front of the

Strip Plate.Activate the PAUSE Key Self Test by pressing the PAUSE Key whileturning the Printer Power ON.After printing a few labels, PAUSE the printer and reduce the DARKNESSvalue until the test labels are a charcoal gray color.Print additional PAUSE Key Self Test labels and observe the print quality.If lighter or no printing is observed on one side of the label as comparedwith the other, continue with this adjustment.Using a 7/64 Allen wrench, slightly loosen the 2 Allen Set Screws mountedon the Wear Plate.Continue to print PAUSE Test labels while adjusting the Wear PlateEccentric for even printing.Adjust the Wear Plate Eccentric by turning it by hand or with a 7/16 openend wrench or with a pair of utility pliers.Adjust the Wear Plate Eccentric clockwise to increase pressure on the MainFrame side of the label or adjust it counter-clockwise to increase pressureon the outboard side of the printer.When even print quality is achieved, hold the Wear Plate in position andtighten the 2 Wear Plate Set Screws.Continue to print PAUSE Test labels and verify Parallelism is correct.If Parallelism is out of tolerance, perform the Printhead ParallelismAdjustment.If no other adjustment is required, align the Strip Plate and tighten the 2Phillips screws.

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Printhead Position Adjustment

This adjustment is performed in conjunction with the Printhead Parallelism,Wear Plate Position, and Printhead Pressure Adjustments.Adjusting the Printhead position aligns the head for optimum print quality.Refer to Figure 5.3 for location of adjustment screws used in the followingprocedure.1.2.3.4.

The thermal elements of the Printhead should be aligned just behind thecrest of the Platen Roller.Print test labels using the PAUSE Key Self Test.Set the Darkness to achieve as close to optimum print quality as possible.Using a 7/64" Allen wrench, loosen the four Allen screws at the top rear ofthe Print Mechanism.CAUTIONIn step 5, to prevent Printhead damage, loosen the four topscrews before turning the two rear adjustment screws.

5.

Adjust the Printhead position for optimum print quality by equally turningthe two screws located at the back of the print mechanism.

Adjustments are made in very small increments.

Turn both screws one eighth turn clockwise and observe the changes in printquality. Turn both screws 1/8 turn counter-clockwise and observe thechanges in print quality. (Due to spring pressure, there may be a dead spotin the actual Printhead movement when switching adjustments from onedirection to the other.)6. Enter the configuration mode and decrease the Darkness until the PAUSETest labels are a charcoal gray color.7. Carefully look at the PAUSE Test labels for streaks, flouring, and otherprint quality problems.8. If required, adjust the hex head screws and observe if print quality problemsare corrected.9. Enter the configuration mode and increase the Darkness until the PAUSETest labels are printed at optimum resolution and contrast.10. Since Printhead parallelism, Wear Plate position and Printhead position areinterrelated, carefully look at the test labels for changes in these settingsand adjust if necessary.

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Printhead Pressure Adjustment

Printhead Pressure is the fourth of the four interrelated adjustments. Using lowerPrinthead Pressure and Darkness settings can extend Printhead life. If printing istoo light on one side, or if thick media is used, Printhead Pressure may requireadjustment.Refer to Figure 5.4 for the location of the Pressure Toggles. The 90XiII printeruses only one toggle which should be positioned over the center of the mediawidth. The 140XiII, 170XiII, and 220XiII printers have two toggles. Thesetoggles are typically positioned at the 1/4 and 3/4 positions across the width ofthe media. If the media is sufficiently narrow that both toggles will not fitwithin its edges, the inside toggle should be centered above the media and theoutside toggle should be reduced to a minimum.1.2.3.4.5.6.

7.

Print PAUSE Key Self Test labels to check print quality.

To increase Printhead Pressure, loosen the Upper Knurled Nut on the Toggleand adjust the Lower Toggle Adjusting Nut downwards.To decrease Printhead Pressure, loosen the Upper Knurled Nut and adjustthe Lower Toggle Adjusting Nut upwards.Adjust Printhead Pressure for optimum print quality.To lock the toggle pressure, tighten the Upper Knurled Nut against theLower Toggle Adjusting Nut.Though different media and ribbon combinations may require differentToggle settings, a suggested initial distance between the flat area at thebottom of the Printhead Pressure Bracket and the top of the upper knurledadjustment nut is 8mm.Enter the configuration mode and set the Darkness to the optimum level forthe installed media.

ADJUSTINGNUTS48452L Rev. 2

Figure 5.4 Printhead Pressure Adjustment

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Strip Plate Adjustment

The Strip Plate Adjustment is a very important part of total printhead adjustmentprocedure.The Strip Plate can be adjusted for proper tracking and separation of the ribbonfrom the media after printing. Refer to Figure 5.3.1.2.3.4.

5.

Print PAUSE Key Self Test labels.

Press the PAUSE Key and, after the printer pauses, observe the ribbon forpossible problems such as wrinkling.Loosen the two Phillips screws holding the Strip Plate to the front of thePrinthead Assembly.While running the PAUSE Key Self Test, lower the Strip Plate so that theribbon is flat and smooth and tracks properly when fed to the RibbonTake-up Spindle.Tighten the Strip Plate Phillips screws and print a minimum of 25 labelswhile checking for ribbon wrinkle, tracking and media/ribbon separationproblems. (If ribbon problems persist, check the torque settings of theRibbon Supply Spindle and adjust tension if required.

Darkness AdjustmentDue to differences in types of media/ribbon and wear on Thermal PrintheadElements, it may be necessary to adjust the Darkness Setting (Burn Temperature) of the XiII Printhead to achieve proper printing. This adjustment is accomplished by using the LCD Display and the Membrane Keys.NOTE: Turning the Printer OFF is not required for the new setting to take effect.To adjust the Darkness, follow the procedure below:CAUTIONSet the Darkness to the lowest setting possible for the desiredprint quality. Darkness set too high for a given ribbon maycause ink smearing, ribbon wrinkle and/or burning throughof the ribbon, as well as reduced printhead life.

1.2.

Page 5-16

Begin printing a batch of labels. Refer to Section 3 and use the Pause Keyand Cancel Key Self Test Label or, preferably, one of your own formats.(Refer to the Printer Configuration discussion in the User Guide.) Using theFront Panel Display and the Membrane Keys, adjust the Darkness Setting toobtain the desired print quality. Decreasing the value in the display causes alighter (less black) image. Increasing the value causes a darker (more black)image.

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Media Tear-Off Position Adjustment

Refer to Figure 5.5. This adjustment sets the rest position of the media over theTear Bar after printing. To achieve the desired Tear-Off position refer to the usersguide. Power need not be turned OFF to set this parameter.

This illustration shows how higher values move the label further out fromthe printer (moves the tear line closer to the leading edge of the next label)while lower values move the label into the printer (moves the tear linecloser to the edge of the printed label).Figure 5.5 Tear-Off Position Adjustment

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Transmissive Media Sensor Position Adjustment

The Transmissive Media Sensor senses either the web between labels or a holeor notch in the print media to determine the length of the label or ticket.The factory-set position should be sufficient for any width label when usingmedia with a web, so little or no repositioning should be required. If it doesbecome necessary to reposition the Transmissive Media Sensor, refer to Figures5.6 and 5.7 and perform the Upper Media Sensor Adjustment followed by theLower Media Sensor Adjustment.To adjust the Upper Media Sensor for the inside half of the media width,follow these steps:1. Remove the ribbon and locate the Upper Media Sensor.2. (90XiII/140XiII/170XiII) Carefully loosen the Phillips screw located at thetop of the sensor.

3.

(220XiII) DO NOT loosen the Phillips screw.

Slide the Upper Sensor along the slot to the desired position.

4.

(When using label stock that has a web between labels, position the UpperMedia Sensor anywhere along the web, except where the rounded corners ofthe label are detected. When using tag stock, position the Upper Sensordirectly over the hole or notch.)Tighten the Phillips screw.

To adjust the Upper Media Sensor for the outside half of the mediawidth, follow these steps:1.2.3.

4.

Remove the ribbon and locate the Upper Sensor.

Remove the Phillips screw. This releases the Upper Sensor and the SensorWire Cover.Lift the Upper Media Sensor Assembly and move the sensor and the wirecover to the outside half of the mounting bracket. Carefully pull the wiresthrough the tie wrap. You may need to set aside the Sensor Wire Cover ifthe adjustment is far to the outside.Replace and tighten the Phillips screw.

To adjust the Lower Media Sensor, follow these steps:

1.2.3.

Locate the Lower Media Sensor assembly (a spring clip holding a circuitboard) under the Rear Idler Roller.Position the Sensor by sliding it in its slot, so that the two brass coloredinfra-red emitters are centered under the Upper Sensor.Gently pull wires out as required. (Wires should have a little slack.)

NOTE: If the Sensor is being moved inward and a large loop of wire results, remove thecover from the Electronics side of the printer and gently pull the wires through.It is important that the wires be properly clamped so that they do not rub anydrive belts.

Page 5-18

XiII-Series Maintenance Manual

48452L Rev. 2

Corrective Maintenance

UPPERMEDIA SENSORADJUSTMENT

220XiII PRINTER ONLY

Figure 5.6

Upper Media Sensor Position Adjustme nt

LOWERMEDIA SENSOR

Figure 5.7 Lower Media Sensor Position Adjustme nt

Reflective Media Sensor Adjustment

The Reflective Media Sensor is placed into operation for those applicationswhere the sensing of Black Marks on the underside of the media is desired. Forthe XiII-Series printers, the position of the Reflective Media Sensor is fixedagainst the Mainframe and has no adjustment. Refer to the printer users guideto configure the printer for operation with either the Reflective Media Sensor orthe Transmissive Media Sensor previously discussed.

48452L Rev. 2

XiII-Series Maintenance Manual

Page 5-19

Corrective Maintenance

LCD Viewing Adjustment

The brightness of the Liquid Crystal Display (LCD) may be adjusted for optimalviewing. Refer to the LCD ADJUST configuration parameter in the printersusers guide.

Motor Balance Adjustment

DO NOT ADJUST THIS SETTING It is for technical use only. The motorbalance is set at the factory. Call Zebra Technical Support with any questions.

Take Label Sensor Alignment

The Take Label Sensor activates only when the Zebra Xi II is set to Peel-Off Mode.This mode requires the media rewind spindle option. The media sensor pair is NOTinstalled on Zebra Xi II printers without this option.Refer to Figure 5.8 for the location of the Take Label Sensor components. Whenthe beam is broken, the Xi II printer will be inhibited from printing or feeding (inPeel-Off Mode only). It may, however, accept additional label formats if thebuffer is not full. There is no sensitivity adjustment for the Take Label Sensor. Ifyou encounter problems, make certain the Xi II printer is set to Peel-Off modeusing the front panel display and that the sensors are aligned. Sensors arealigned at the factory or when the media rewind spindle option is installed. Noadjustments are required after installation.

LABELAVAILABLESENSORS

Figure 5.8 Take Label Sensor Location

Page 5-20

XiII-Series Maintenance Manual

48452L Rev. 2

Corrective Maintenance

Media Tracking Adjustments

Rewind ModeIf the media walks from side to side, tears, or wrinkles against the MediaRewind Tracking Plate, it will be necessary to adjust the Rewind PlateAssembly. Refer to Figures 5.9 and 5.10.1.

2.3.

4.

5.

Remove the Rewind Plate Assembly and loosen the 5/16 Hex Nuts (01130)which attach the Hook Plate to the Rewind Plate. Moving the outer end ofthe Hook Plate up will force the media towards the Rewind Tracking Platewhile moving this end down will move the media away from the TrackingPlate. (The opposite effect will occur if the same adjustments are performedon the inner end of the Hook Plate.)Reinstall the Rewind Plate Assembly and print a number of test labels. Ifproblems persist, readjust the Hook Plate.If the media cannot be made to track correctly with this adjustment, checkthe distance from the outside of the Tracking Plate to the Main Frame. Thisdimension is set at the factory and should be 0.547 (13.9 mm) to 0.567(14.4 mm). If the distance needs to be reset, refer to Figure 5.10 andproceed to step 4 below.Use a 1/16 Hex Allen Wrench to loosen the two set screws in the Collarlocated inside the Rewind Spindle Assembly. The screws are accessiblethrough a single hole in the Spindle Assembly, as shown in Figure 5.10.Reposition the Spindle Assembly closer to or farther from the Main Frameas required, and retighten the two collar set screws.Perform steps 1 and 2 until required results are achieved.

01130

Figure 5.9 Rewind Plate Assembly

48452L Rev. 2

XiII-Series Maintenance Manual

Page 5-21

Corrective Maintenance

Figure 5.10 Rewind Spindl e Positioning

Peel-Off ModeIn PEEL-OFF MODE the Lower Roller alignment has the same affect onmedia tracking as the Rewind Plate alignment does in REWIND MODE. Referto Figure 5.11 and perform the following procedure.1. Use a 7/64 Hex Allen wrench to loosen the two Allen Head screws which attachthe Platen Support Bracket to the Side Plate.2. Moving the Bracket toward the front of the machine moves the labelbacking material away from the Rewind Tracking Plate. Moving the Brackettoward the rear of the machine moves the label backing toward the TrackingPlate. Adjust Bracket position as required and tighten the Allen Headscrews.3.Repeat steps 1 and 2 until required results are achieved.

7/64" HEXALLENSCREWSLOWERROLLER

PLATENSUPPORTBRACKET

Figure 5.11 Peel-Off Lower Roller Alignment

Page 5-22

XiII-Series Maintenance Manual

48452L Rev. 2

Corrective Maintenance

Spindle Adjustment and Maintenance

There are four spindles which require periodic tension measurement andadjustment. Measuring spindle tension should be done at least once each yearunless required more often due to high printer use. Tension should be adjustedwhenever it is not within the tolerance range associated with that spindle.

Tension Measurement Procedure

The procedure for measuring spindle tension is similar for all four spindles.Refer to the Spindle Tension Adjustment Diagram in Figure 5.12 for anyspecific requirements.1. Use adhesive tape to attach a 2 wide strip of polyester film (part # 01776)to the Spindle Shaft (or Core where required) as illustrated in Figure 5.12.Wind the polyester film around the Spindle (or Core) about 5 times in thedirection indicated.2. Measure tension by slowly pulling the film with a springscale. Pull ONLYin the direction shown. The pull rate should typically be 2 per second.3. Compare the springscale reading with the force values provided in Figure5.12. Perform the Spindle Adjustment only if the reading is out of spec.4. If adjustment is made, recheck the tension after running a full roll of labels.

Spindle Tension Adjustment

Refer to the Spindle Tension Adjustment Diagram in Figure 5.12 and adjust theSpindle Tension as follows:1. Loosen the set screw(s) if present in the Adjustment Nut at the end of theSpindle.2. Turn the Adjustment Nut clockwise to increase the tension or counterclockwise to decrease the tension. Tighten the set screws if present.NOTE: If the shaft of the Ribbon Take-Up, Media Take-Up or optional Media SupplySpindle turns when attempting to turn the Adjustment Nut, refer to Figure 5.10and insert an Allen wrench through the access hole on the inner end of thespindle and into the set screw in the shaft collar. DO NOT TURN THE ALLENWRENCH. Simply hold the shaft in place with the Allen wrench while turningthe Adjustment Nut.3.

Measure the spindle tension as performed above. Compare the tension readingon the springscale with the appropriate force value provided in Figure 5.12.Repeat the adjustment procedure until the correct tension is obtained.

Spindle MaintenancePeriodic spindle maintenance is not required on the XiII-Series printers.

WARNINGDO NOT apply lubrication to any ofthe spindles in the XiII-Series printers.

48452L Rev. 2

XiII-Series Maintenance Manual

Page 5-23

Corrective Maintenance

ALIGN ALL THREE SECTIONS

BEFORE INSTALLING RIBBON CORE.

F1

RIBBON SUPPLYSPINDLE ASSY

90XiII

SPINDLE (FORCE)

140XiII(GRAMS)

(GRAMS)

170XiII

220XiII

(GRAMS)

(GRAMS)

RIBBON SUPPLY (F1)

450 50

450 50

500 50

600 50

RIBBON TAKEUP (F2)

450 50

450 50

550 50

630 50

MEDIA SUPPLY (F3)

300 50

300 50

300 50

300 50

MEDIA REWIND (F4) 1450 100 1450 100 1650 100 1830 100

ATTACH POLYESTERFILM STRIP TORIBBON COREWITH TAPE

F3

MEDIA SUPPLYSPINDLE ASSY

F2

MEDIACORE

DETAIL AMORE LOAD

RIBBON TAKEUPSPINDLE ASSYSETSCREWS(1 or 2)

F4

LESSLOAD

LOOSEN THE SET SCREWS ON THE

ADJUSTING NUT. TURN THE NUTIN/OUT TO INCREASE/DECREASETHE FORCE. AFTER ADJUSTMENT,SECURE THE NUT TO THE SHAFTWITH THE SET SCREWS.

MEDIA REWINDSPINDLE ASSY

MEDIACORE

Figure 5.12 Spindle Tension Adjustments

Page 5-24

XiII-Series Maintenance Manual

48452L Rev. 2

Corrective Maintenance

Removing the Main Logic Board

The Xi II-Series Main Logic Board may require removal when replacement isnecessary or when installing various options in the field. Follow the procedurebelow to remove the XiII-Series Main Logic Board.CAUTIONThe printer electronics are susceptible to static discharge. Beforeproceeding, it is highly recommended the Technician wear ananti-static wrist strap connected to the printer chassis.

1.2.3.4.5.6.7.8.

9.

Be sure the printer is OFF and the AC Power Cord and Signal InterfaceCable are disconnected.Remove the Left Side Panel of the printer by removing the Phillips screwswhich hold it on.Remove any Font Card or Memory Card from the card slot located at therear of the printer, by pressing the card release button.If an optional interface board is installed in the printer, refer to the removalinstructions for that board before continuing this procedure.Refer to Figure 5.13. Unplug all Ribbon Cable Connectors and Small WireConnectors from the Main Logic Board (note their positions).Refer to Figure 5.14. At the rear of the printer, remove the 4 Phillips screwsholding the serial and parallel interface connectors to the back of the printer.Remove the Main Logic Board by squeezing the tips of the plasticstand-offs at the top and bottom right hand corners of the board.Software is not included with the replacement Main Logic Board. Refer tothe Program ROM Installation topic covered later in this section, and use aZebra-approved PLCC (Plastic Leaded Chip Carrier) Extraction Tool tocarefully remove the program ROMs and any optional Font ROMs from thefaulty Main Logic Board. Carefully install the ROMs on the replacementboard. (The label on each ROM specifies the chip location on the MainLogic Board.)Perform the Installation Procedure below, being very careful with all cables.

Installing the Main Logic Board

Follow the procedure below to install the XiII-Series Main Logic Board.1.

Refer to Figure 5.13 and Table 5.1 and place Rotary Switch S1 in theproper position for the printer under repair. (Rotary Switch S2 mustremain in the zero (0) position.)(this procedure continues on page 5-24)

Figure 5.13 Circuit Board Location and Interconnection

STEPPERMOTORLCD DISPLAYCUTTER OPTION

Corrective Maintenance

2.

Refer to Figure 5.14. Position the cables out of the way while placing theMain Logic Board onto the plastic stand-offs at the top and bottom righthand corners of the board.3. At the rear of the printer, install the 4 Phillips Screws which hold the serialand parallel interface connectors to the back of the printer.4. Refer to Figure 5.13. Carefully connect all the Ribbon Cables and SmallWire Cables to the proper connectors on the Main Logic Board.5. Refer to Figures 5.14. If required, install the optional interface boardthrough the rear of the printer. (Insure the data cable is properly connectedbetween the Main Logic Board and the Interface Board6. If required, install any Font Card or Memory Card into the card slot locatedat the rear of the printer.7. Reconnect the AC Power Cord and the Signal Interface Cable.8. Turn the printer ON and configure the printer parameters. Be sure to enterthe Printhead Resistance value indicated on the label attached to theprinthead9. Hold in the PAUSE Key while turning the AC Power ON. Observe theprinter Power ON Self Test and examine the test labels which print forproper print quality.10. Reinstall the Left Side Panel.11. Refer to the printers users guide and program the Printer Parameters.NOTE: During the programming process, you must perform a complete PrinterCalibration. (Pressing the Front Panel CALIBRATE Key will not provide thefull calibration process required when a Main Logic Board is first installed.)Refer to page 5-2 to begin the Configuration and Calibration process.12. When the Printer Parameters are programmed and SAVED, turn the printerOFF and back ON to activate the new parameters.Table 5.1

S1 Switch Settin gs

SwitchPosition

Function

SwitchPosition

Function

Diagnostics

140XiII KMT (8 dots/mm 8"/sec max)

170PAX Left Hand (12dots/mm)

140XiII KST (8 dots/mm 8"/sec max )

170PAX Right Hand (12dots/mm)

140XiII KMT (8 dots/mm 12"/sec max)

170PAX Left Hand (8dots/mm)

140XiII KST(8 dots/mm 12"/sec max)

170PAX Right Hand (8dots/mm)

Undefined

Undefined

Undefined

90XiII Printhead (12 dots/mm)

220 XiII Printhead (8 dots/mm)

Undefined

170XiII Printhead (12 dots/mm)

48452L Rev. 2

XiII-Series Maintenance Manual

Page 5-27

Page 5-28

OPTIONALINTERFACEBOARD

Corrective Maintenance

XiII-Series Maintenance Manual

OPTIONALMEMORYCARD

S1S2

FONTROMS(2)

ROTARYSWITCHES

DC POWER SUPPLY ASSEMBLY

MAIN LOGICPCB

48452L Rev. 2

PROGRAMROMS (4)

HEAT CONDUCTOR PAD

Figure 5.14 Main Logic Board & DC Power Supply Board

Corrective Maintenance

Removing the DC Power Supply Assembly

The Xi II-Series DC Power Supply Assembly may require removal whenreplacement is necessary or when installing various options in the field. Followthe procedure below to remove the XiII-Series DC Power Supply Assembly.CAUTIONThe printer electronics are susceptible to static discharge. Beforeproceeding, it is highly recommended that the Technician wear ananti-static wrist strap connected to the printer chassis.

1.2.3.4.5.6.

Be sure the printer is OFF and the AC Power Cord and Signal InterfaceCable are disconnected.Remove the Left Side Panel of the printer by removing the Phillips Screwswhich hold it on.Refer to Figure 5.13. Unplug all Ribbon Cable Connectors and Small WireConnectors from the DC Power Supply Board (note their positions).Refer to Figure 5.14. Remove the mounting screw and two hex nuts holdingthe DC Power Supply Assembly against the printer chassis.Remove the DC Power Supply Assembly from the printer. (The black heatconduction pad need not be removed.)Perform the Installation Procedure below, being very careful with all cables.

Installing the DC Power Supply Assembly

Follow the procedure below to install the XiII-Series DC Power SupplyAssembly.1.

2.3.4.5.

6.7.

48452L Rev. 2

Refer to Figure 5.14. Position the cables out of the way while placing theDC Power Supply Assembly into the printer. (Insure the heat conductionpad is in powition.)Refer to Figure 5.14. Install the mounting screw and two hex nuts whichhold the DC Power Supply Assembly against the printer chassis.Refer to Figure 5.13. Carefully connect all the Ribbon Cables and SmallWire Cables to the proper connectors on the DC Power Supply Board.Reconnect the AC Power Cord and the Signal Interface Cable.Hold in the PAUSE Key while turning the AC Power ON. Observe theprinter Power ON Self Test and examine the test labels which print forproper print quality. (If necessary, refer to the users guide to configure theDarkness setting.)Reinstall the Left Side Panel.The printer should now be ready for operation.

XiII-Series Maintenance Manual

Page 5-29

Corrective Maintenance

Removing the AC Power Supply Assembly

The Xi II-Series AC Power Supply Assembly may require removal whenreplacement is necessary or when installing various options in the field. Followthe procedure below to remove the XiII-Series AC Power Supply Assembly.CAUTIONThe printer electronics are susceptible to static discharge. Beforeproceeding, it is highly recommended that the Technician wear ananti-static wrist strap connected to the printer chassis.

1.2.3.

4.5.6.7.8.

9.

Be sure the printer is OFF and the AC Power Cord and Signal InterfaceCable are disconnected.Remove the Left Side Panel of the printer by removing the Phillips Screwswhich hold it on.Refer to Figure 5.13. Unplug all Ribbon Cable Connectors and Small WireConnectors from the Main Logic Board and AC Power Supply Board (notetheir positions).Remove the hex nut holding the ground lead from the Power Entry Moduleto the printer chassis.Refer to Figure 5.15. Remove the 2 screws at the top and center right handcorners of the metal mounting plate directly behind the Main Logic Board.At the rear of the printer, remove the 3 Phillips screws holding the rearpanel to the back of the printer.Slide the Main Logic Board and Rear Panel Assembly out and away fromthe printer.Remove the AC Power Supply Assembly by removing the 5 hex nuts and 2spacers which hold the Assembly against the mounting posts. (The blackheat conduction pad need not be removed.)Perform the AC Power Supply Assembly Installation Procedure below,being very careful with all cables.

Installing the AC Power Supply Assembly

Follow the procedure below to install the XiII-Series DC Power SupplyAssembly.1.

2.

3.4.

Refer to Figure 5.15. Position the cables out of the way while placing theAC Power Supply Assembly into the printer. (Insure the heat conductionpad is in position.)Refer to Figure 5.15. Install the 5 hex nuts and 2 spacers which hold the ACPower Supply Assembly against the printer chassis. (Insure the plasticspacers are installed on the two left posts.)Slide the Main Logic Board and Rear Panel Assembly into the printer.Refer to Figure 5.15. Install the 2 screws at the top and center right handcorners of the metal mounting plate directly behind the Main Logic Board.(this procedure continues on page 5-29)

Page 5-30

XiII-Series Maintenance Manual

48452L Rev. 2

48452L Rev. 2

MAIN LOGIC BOARD

AND REAR PANEL

Corrective Maintenance

XiII-Series Maintenance Manual

ACPOWER SUPPLYASSEMBLY

Page 5-31

HEATCONDUCTIONPAD

Figure 5.15 AC Power Supply Board

Corrective Maintenance

5.

At the Rear of the printer, install the 3 Phillips Screws which hold the rearpanel to the back of the printer.6. Use the hex nut to install the ground lead from the Power Entry Module tothe printer chassis.7. Refer to Figure 5.13. Install all Ribbon Cable Connectors and Small WireConnectors onto the Main Logic Board and AC Power Supply Board.8. Reconnect the AC Power Cord and the Signal Interface Cable.9. Hold in the PAUSE Key while turning the AC Power ON. Observe theprinter Power ON Self Test and examine the test labels which print forproper print quality.10. Reinstall the Left Side Panel.11. The printer should now be ready for operation.

Program ROM Installation

To replace the program ROMs, follow the procedure below. A PLCC (PlasticLeaded Chip Carrier) Extraction Tool is included in the upgrade kit:CAUTIONThe printer electronics are susceptible to static discharge.Before proceeding, it is recommended the Technician wear ananti-static wrist strap connected to the printer chassis.

1.2.3.

4.

Turn the AC Power OFF and disconnect the Power Cord.

Remove the Left Side Panel of the printer by removing the Phillips Screws.Refer to Figure 5.16. Insert the tines at the bottom of the Extraction Toolfirmly into the slots in the chip socket. Make sure the tines catch under theROM chip as you gently squeeze, and the program ROM will raise out ofthe socket. Repeat for positions U4, U12, U20 and U27.Insert the new program ROMs with the notched corner positioned to theupper right or the positioning dot pointing up. Match the Main Logic BoardU position with the position specified on each ROM label. Make sure allpins are properly aligned before pressing the chips into place.(This procedure continues on page 5-30)

GENTLYSQUEEZE

ASSYP/N

13

1966

U19

Zebra Technologies Corporation

5

13

U4

21

U4

C2

13

U12

29

13

U20

U12

C3

21 U20

29

U27

21

U27

29

18

Figure 5.16 Program ROM Replacement

Page 5-32

XiII-Series Maintenance Manual

48452L Rev. 2

Corrective Maintenance

CAUTIONPermanent damage to the ROM will result if you power up theprinter with it installed in the wrong direction.Before you apply Power, double check that all ROMs are inthe proper socket and properly aligned. If you have anydoubts, contact your Distributor or Zebra Technical Support.

5.6.7.

Reconnect the AC Power Cord.

Press and hold the FEED Key while turning the printer Power Switch ON.Verify the version of software printed on the Configuration Label during thePower ON sequence.8. Install the Left Side Panel of the printer by using the Phillips Screws.9. Refer to the printers users guide and program the Printer Parameters.10. During the programming process, you must perform a complete PrinterCalibration. (Pressing the Front Panel CALIBRATE Key will not providethe full calibration required when new printer software is first installed.)11. When the Printer Parameters are programmed and SAVED, turn the printerOFF and back ON to activate the new parameters.

Option InstallationFont ROM InstallationOptional scalable and bit-mapped Fonts are available in ROMs.

11

To install the Font ROMs, refer to Figure 5.17 below and substitute Font ROMfor Program ROM as you follow the Program ROM Installation procedurepreviously discussed.

FontROM

10

Figure 5.17 Font ROM Installation

48452L Rev. 2

XiII-Series Maintenance Manual

Page 5-33

Corrective Maintenance

Memory Card and Font Card Installation

To replace the Memory Card or Font Card, read the instructions included in theoption kit. The general installation procedure is as follows:1.2.3.4.5.6.

7.

Turn the AC Power OFF before installing the card.

Refer to Figure 5.18 and remove the Option Card Shield from the rear of theprinter.Insert the Memory Card or Font Card, with the notch UP, into the card slotas shown. ( Insert far enough to cause the eject button to pop out.)Reinstall the Option Card Shield over the Option Card and card slot.Press and hold the FEED Key while turning the printer Power Switch ON.Verify the presence of additional Memory or optional Fonts by checking theinformation indicated on the Configuration Label printed during the PowerON sequence.The printer is now ready to operate with the additional Memory or Fontoption.

CARD EJECTBUTTON

MEMORY/FONTOPTION CARD

NOTCH

OPTION CARDSHIELD

Figure 5.18 Memory Card and Font Card Installation

Page 5-34

XiII-Series Maintenance Manual

48452L Rev. 2

Corrective Maintenance

SIMM InstallationTo replace the Memory Card or Font Card, read the instructions included in theoption kit. The general installation procedure is as follows:CAUTIONThe printer electronics are susceptible to static discharge.Before proceeding, it is recommended the Technician wear ananti-static wrist strap connected to the printer chassis.

1.2.3.4.5.6.7.

8.

Be sure the printer is OFF and the AC Power Cord is disconnected.

Remove the Left Side Panel of the printer by removing the Phillips screwswhich hold it on.Refer to Figure 5.19 and locate the SIMM Socket on the Main Logic Board.Install the SIMM into the socket as illustrated in Figure 5.19. (Make surethe SIMM is locked securely into position.Reconnect the AC Power Cord.Press and hold the FEED Key while turning the printer Power Switch ON.Verify the presence of additional Memory or optional Fonts by checking theinformation indicated on the Configuration Label printed during the PowerON sequence.The printer is now ready to operate with the additional Memory option.

PCB P/N49701 REV 1

21INSERTSIMM ONANGLE

PUSHTOLOCK

SIDE VIEW

Figure 5.19 SIMM Installation

48452L Rev. 2

XiII-Series Maintenance Manual

Page 5-35

Corrective Maintenance

Main Drive Belt - Removal, Replacement & Adjustment

90XiII, 140XiII and 170XiII (for 220XiII, refer to the following page.)1.2.3.

4.5.6.7.

8.

9.

Turn the printer OFF and remove the AC Power Cord.

Remove the Left Side Panel of the printer by removing the Phillips Screwswhich hold it on.Refer to Figure 5.20 and rotate the Ribbon Take-Up Pulley until the 3 holesin the Pulley are aligned with the 3 mounting screws which hold the RibbonTake-Up Spindle Assembly to the Printer Frame.Use a 9/64 Allen Wrench to reach through the holes in the Ribbon Take-UpPulley and loosen the 3 Spindle Assembly mounting screws.Slide the Ribbon Take-Up Spindle Assembly to the right to relieve thetension on the Main Drive Belt.Remove the old Main Drive Belt and install the new one.Hook a 2200 gram spring scale to the belt as shown in Figure 5.20, andcarefully slide the Ribbon Take-Up Spindle Assembly to the left to increasebelt tension.When a scale reading of 2000 grams 250 grams (4.5 lbs 0.5 lbs) creates adeflection of 1/4 inch, tighten the 3 mounting screws to a torque of 20inch-pounds.Replace the Left Side Panel and reapply AC Power.

ACCESS TOMOUNTINGSCREWS

322200

2018

00

1 SHENC

00

1600

1400

SPRINGSCALE

Figure 5.20 90/140/170XiII Main Drive Belt

Page 5-36

XiII-Series Maintenance Manual

Turn the printer OFF and remove the AC Power Cord.

Remove the Left Side Panel of the printer by removing the Phillips Screwswhich hold it on.Refer to Figure 5.21 and note the position of the Idler Gear used to adjustthe tension of the Main Drive Belt.In the Media Compartment, locate the Idler Gear Mounting Screw. Use a7/64 Allen Wrench to loosen the Idler Gear Mounting Screw.Refer to Figure 5.21 and slide the Idler Gear Assembly toward the rear ofthe printer to relieve the tension on the Main Drive Belt.Remove the old Main Drive Belt and install the new one.Hook a 2200 gram spring scale to the belt as shown in Figure 5.21, andcarefully slide the Idler Gear Assembly toward the front of the printer toincrease belt tension.When a scale reading of 2000 grams 200 grams (4.5 lbs 0.5 lbs) creates adeflection of 1/4 inch, tighten the Idler Gear Mounting Screw.Replace the Left Side Panel and reapply AC Power.

IDLERGEAR

32

2200

2000

1800

00

00

14

16

1 SHEINC

SPRINGSCALEFigure 5.21 220XiII Main Drive Belt48452L Rev. 2

XiII-Series Maintenance Manual

Page 5-37

Corrective Maintenance

Rewind Drive Belt - Removal, Replacement & Adjustment

1.2.3.4.

5.6.7.8.

9.

Turn the printer OFF and remove the AC Power Cord.

Refer to page 5-26 and remove the DC Power Supply from the Printer.Refer to Figure 5.22 and note the position of the Idler Gear used to adjustthe tension of the Rewind Drive Belt.On the Media Side of the printer, locate the lower access hole in the SideFrame and remove the hole plug. Use a 7/64 Allen Wrench with a 10minimum shaft length (90/140/170XiII) or a 12 minimum shaft length(220XiII) to reach through the hole and loosen the Idler Gear MountingScrew.Slide the Idler Gear Assembly toward the front of the printer to relieve thetension on the Rewind Drive Belt.Remove the old Rewind Drive Belt and install the new one.Hook a 2200 gram spring scale to the belt as shown in Figure 5.19, andcarefully slide the Idler Gear Assembly to the left to increase belt tension.When a scale reading of 2000 grams 250 grams (4.5 lbs .5 lbs) creates adeflection of 1/4, tighten the Idler Gear Mounting Screw to a torque of 20inch-pounds.Refer to page 5-26 and perform the DC Power Supply Installation procedure.

14001600180020002200

1INCHES

IDLERGEAR

23

Figure 5.22 90/140/170/220XiII Rewind Drive Belt

Page 5-38

XiII-Series Maintenance Manual

48452L Rev. 2

Corrective Maintenance

AC Power Fuse Replacement

The XiII-Series printer uses a metric-style fuse (5 x 20 mm IEC) rated at F5A,250V. The AC Power Entry Module comes with two approved fuses in the FuseHolder: one is In-Circuit and the second is provided as a spare (refer to Figure5.23 below). The end caps of the fuse must bear the certification mark of aknown international safety organization (refer to Figure 5.24). To replace afaulty fuse, use the following procedure.

WARNINGTurn the printers AC Power Switch OFF and disconnectthe printers AC Power Cable before replacing any Fuses.

1.

Refer to Figure 5.23. Using a small blade screwdriver or similar tool,

remove the Fuse Holder which is part of the AC Power Entry Module at therear of the printer.2. Remove the faulty fuse and install a new fuse in the In-Circuit position. Ifyou use the Spare Fuse, be sure to order a new replacement fuse. Fuses canbe ordered from your Zebra distributor.3. Snap the Fuse Holder back into the AC Power Entry Module.4. Reconnect the Power Cable and turn printer ON.NOTE: If AC power is not restored, an internal component failure may haveoccurred. The printer will require servicing.

1. Load ribbon correctly.

Check Head Open Sensor and

Printer stops and

Check Media Sensor

Position and Sensitivity.Install proper Media or resetprinter for current Media type.

Head Open Sensor not detecting

Position Flag or Flag not in theproper position.Printhead elementis overheated.

Printer stops and

ERROR LED Flashes.WARNINGHEAD UNDERTEMP

ACTION

Load media correctly.

Printer resumes printing when the

Printhead element cools to anormal operating temperature.

XiII-Series Maintenance Manual

48452L Rev. 2

Troubleshooting

Table 6.2 Error Messages (Cont'd)

SYMPTOM

Printer stops and

PAUSE LED lights.LCD displays:

DIAGNOSIS

Not enough memory to perform

the function indicated in thesecond line of the display.(It is possible that the printer isconfigured for Continuous LabelStock with the Maximum LabelLength set too long.)Functions:

OUT OF MEMORYCREATING BITMAPOUT OF MEMORYSTORING BITMAPOUT OF MEMORYBUILDING FORMATOUT OF MEMORYSTORING FORMATOUT OF MEMORYSTORING GRAPHICOUT OF MEMORYSTORING FONT

48452L Rev. 2

1. Creating a Bitmap - Bitmap

size is larger than the labellength/width specified.2. Storing a Bitmap - Notenough memory availableto store the Bitmap created.3. Building a Format - Labelis too complex.4. Storing a Format - Formatsize is too large to fit inavailable memory.5. Storing a Graphic - Graphicimage is too large to fit inthe available memory.6. Storing a Font - notenough memory to storethe font.

ACTION

You may do any of the

following:A. STORING ERRORS With PAUSE ON, use the~HM ZPL II Command todisplay the amount ofmemory available. Thenredesign the graphic/formatto fit in the available memoryor remove items from memory to create more space.orPress PAUSE to skip that stepin the process and continue tothe next step.B. With PAUSE ON, pressCANCEL and the printerskips that label formattingprocess and continues to thenext label format.C. Turn Power OFF to Clearprinter memory and start allover again.

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Table 6.3 Troubleshooting

SYMPTOM

Poor Print Quality.

DIAGNOSIS

ACTION

Darkness set too low.

Reconfigure Darkness setting.

Incorrect Mediaand Ribbon.

Replace Mediaand Ribbon.

Printhead just replaced.

Insure Printhead is installed

properly with no wires ordebris caught underneath.

Printhead Adjustmentsincorrect.

Perform requiredadjustments.

Printhead Resistance not

configured to proper value.

Reconfigure PrintheadResistance.

Truncated print, no print, or

Feed button operatesincorrectly while usingnon-continuous media.

Maximum label length

parameter set less than theactual label length.

Set the correct

label length.

Printer, that is in Rewind or

Peel-Off Mode, waspowered ON without mediaor backing around theRewind Spindle.

Prefix and Delimiter

Set the characters in the

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Sample LabelsThe following pages contain labels to be used with the preceedingtroubleshooting charts. These labels illustrate conditions which could be seen ifmechanical adjustments are necessary.Zebra type 3P Media Stock and type 5319 Ribbon were used to obtain theselabels. Any other Label and Ribbon stock combinations may produce samplelabels with similar but not necessarily the same indications.The size of these example labels has been adjusted to permit good visibility ofthe effects of the mechanical problem being illustrated.

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Factory AssistanceShould any problem be encountered which cannot be corrected with the aid of thismanual, immediately contact your Distributor or the Zebra Technical SupportDepartment to minimize downtime and/or assist in returning the equipment.

Returning EquipmentShould it become necessary to ship your XiII-Series printer, carefully pack it in asuitable container to avoid damage during transit. A note describing the failure must beenclosed with the unit. Whenever possible, the original shipping container should beused. If the original shipping container is not available, a replacement can be orderedby contacting the Technical Support Department. If other containers are used, aprocedure similar to the original factory packaging should be followed.Remove all media and ribbon from the printer. Enclose the unit in aprotective, dust-proof bag and insure that the unit floats in an outer carton ofshock absorbing material.A Return Materials Authorization (RMA) number is required for all equipmentbeing returned. Contact Zebra Technologies Corporations Technical SupportDepartment to obtain an RMA number. Equipment returned for service withoutprior authorization may be refused.

CAUTIONBefore packing the printer, remove any ribbon and paperrolls from the media compartment. DO NOT package theprinter in a rigid container without utilizing shockmounts orshock-absorbing packing material. A rigid container willallow shock on the outside to be transmitted undamped tothe unit and may cause damage.

Printer Test Overview

This Maintenance Manual does not contain a Circuit Description section.Instead, this section of the manual provides in-depth explanations of theoperation and testing features of the XiII-Series printers. Faulty ElectronicAssemblies should be easily located by board swapping. Further diagnostictesting of the faulty electronic assembly should be performed at a depot- levelstyle repair facility.

Power ON Self Tests

The printer performs a complete self test sequence each time power is turnedON. This sequence of tests verifies that the printer will perform as required.Failing a critical test stops the printer from completing the self-test and stopsnormal printer operation. The following are the tests and their results.

LED TestAll LEDs are turned ON. Visual inspection by the operator is required to verifythat all LEDs are operational.

Program ROM CRC Test

This test takes less than 5 seconds to execute. The CRC value for programmingcode memory space is calculated and compared to the last few bytes of the codeitself. The Program ROMs are operational when the calculated CRC valuematches the CRC value stored at the end of the ROM memory.Upon successful completion of the ROM test the Data LED is turned OFF.Should the CRC test fail, the system will not advance beyond this test.

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DRAM TestThis test takes less than 5 seconds to execute.DRAM (Dynamic RAM) operation is verified by reading and writing to theDRAM area. The test is successful if one megabyte or more of DRAM isproperly functioning. The DRAM size is rounded down to one, two, four, oreight megabytes available.If the test finishes successfully, then the entire DRAM space is initialized tozero. After the memory is initialized, the Pause LED is turned OFF.The Configuration Label and the LCD Idle Message show the amount of memoryrecognized. This value is compared to what was installed in the unit, to verifythat all of the installed memory is functioning correctly.Should the DRAM test fail, the system will not advance beyond this test. Thefailed DRAM area will be read repeatedly until power is turned OFF.

Printer Type Test

This test checks the settings of the Printer Type Selector Switches (S1 and S2)located on the Main Logic Board. When the Main Logic Board is installed, S1must be positioned according to the type of printer. S2 must be in the zero (0)position.Table 7.1 shows the valid settings for S1. This switch should not be set to theZERO (0) position unless a faulty Main Logic Board is being tested. Refer topage 7-20 for further information on the Diagnostic Tests.CAUTIONInsure this switch is properly positioned before applying Powerto the printer. If this switch is set incorrectly, the Printhead or theMain Logic Board could be damaged.

Table 7.1

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S1 Switch Settings

SwitchPosition

Function

SwitchPosition

Function

Diagnostics

140XiII KMT (8 dots/mm 8"/sec)

170PAX Left Hand (12dots/mm)

140XiII KST (8 dots/mm 8"/sec)

170PAX Right Hand (12dots/mm)

140XiII KMT (8 dots/mm 12"/sec)

170PAX Left Hand (8dots/mm)

140XiII KST(8 dots/mm 12"/sec)

170PAX Right Hand (8dots/mm)

Undefined

Undefined

Undefined

90XiII Printhead (12 dots/mm)

220 XiII Printhead (8 dots/mm)

Undefined

170XiII Printhead (12 dots/mm)

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LCD Display Test

The LCD (Liquid Crystal Display) shows all the displayable characters. Thedisplay then shows solid boxes at each character position allowing the operatorto visually insure all dot positions are displayable.

Shared SRAM Test

This test takes less than 2 seconds.The LCD displays SRAM test. The shared SRAM (Static RAM) operation isverified by reading and writing to the SRAM area. The testis successful when the full 128k of SRAM is properly functioning.If the test finishes successfully, then the entire SRAM space is initialized tozero, and the Paper Out LED is turned OFF. After memory is cleared, the codefor the second processor is loaded into memory and the second processor startsexecuting the code.Should the SRAM test fail, the system will not advance beyond this test. Thefailed SRAM area will be read repeatedly until power is turned OFF.

Second Processor Test

This test takes less than 5 seconds to execute.The LCD displays Processor Test. The CRC value for shared SRAM space iscalculated by the second processor and compared to the expected value. Thesecond processor is operational when the CRC values match. The mainprocessor will wait for the second processor to finish this test.Should this test fail, the system will not advance beyond this CRC test.

Optional ROM CRC Test

This test takes less than 5 seconds to execute.The LCD displays the phrase Option ROM Test. The CRC for each object inthe optional ROM is calculated and compared to the expected CRC. All of theobject CRCs must match for the optional ROM to be valid.Should the option ROM CRCs not match, the display will show Not Installedand the system will pause for one second.

EEPROM Checksum Test

The LCD displays the phrase EEPROM Test. A checksum is calculated foreach value stored in the EEPROM. If the checksum is correct, the correspondingprinter parameter is updated. Should any value be incorrect, the factory defaultsetting is loaded for that value and the LCD displays the phrase Failed for onesecond. See the LCD Menu operation described later.

Printhead TestThe LCD displays the phrase Print Head Test. The printhead test determinesthe width and dot density of the printhead. The printer operation is then adjustedaccordingly. This test actually checks rotary switches SW1and SW2 and not theprinthead itself.

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Memory Card Test

This test takes less than 5 seconds to execute.The LCD displays the phrase Memory Card Test. The CRCs for objects in theoptional memory card are calculated and compared to the CRCs in the card. Allof the object CRCs must match for the option card to be valid.Should the option card CRCs not match, the display will show Not Installedand the system will pause for one second.

Test CompletionThe final action of the Power On Self Tet is to turn all of the LEDs OFF exceptthe Power LED. At this time the LCD displays the phrase Printer Ready.

Power-Up Media Registration

Once the Power On Self Test is complete, if the Printhead Type Selector Switch(S1) is not 0", the media is advanced to the proper rest position. Continuousmedia is assumed to be at the proper rest position. The motion required to placenon-continuous media at the rest position is determined by the media feedsetting. Both the printer configuration and a ZPL command can set the mediafeed value to one of four possible values. No Motion - this indicates that the media is correctly positioned and nomotion is required. Feed - (Default) this causes the media to feed to the first web, notch, hole,or mark that passes the media sensor. Length - the printer measures the length of one label and then feeds to thestart of the next label. Calibrate - the printer performs a full calibration where the media type,label length, and sensor settings are determined prior to feeding the nextlabel to the rest position.The proper rest position is determined by the print mode, which isdescribed later.

Self-Test LabelsSelf-test labels, if requested, are generated once the media registration iscompleted. These self-test labels are requested by pressing a key while turningthe printer power ON. (The key must be held in before the power is turned onand not released until the first LED turns OFF.) The PAUSE Key Self-Test andthe FEED Key Self-Test both cause labels to print. The label formats changewhen a loopback connector is detected.

PAUSE Key and FEED Key Self-Test (Reset Defaults)

Pressing the PAUSE and FEED Keys while turning printer power ON resets theprinter to the Default settings.These values are not saved in EEPROM, but may be saved from the LCD menu.

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PAUSE Key Self-Test (Head Alignment and Run-in Tests)

This test starts with a check of the hardware handshake lines. When a loopbackconnector is not detected, the following printhead test labels print. When theprinter pauses during these formats, pressing the PAUSE Key re-starts printing.While paused, pressing the CANCEL Key switches to the next set of labels. Thistest can be performed without a loopback connector.Eight dots per millimeter test sequence: 9999 labels at two inches/second pausing every 15 labels 9999 labels at eight inches/second pausing every 15 labels 9999 labels at two inches/second pausing every 50 labels 9999 labels at eight inches/second pausing every 50 labelsTwelve dots per millimeter test sequence: 9999 labels at two inches/second pausing every 15 labels 9999 labels at six inches/second pausing every 15 labels 9999 labels at two inches/second pausing every 50 labels 9999 labels at six inches/second pausing every 50 labelsWhen the loopback connector is detected, 500 Head Test labels are printed at sixinches per second. The printer places the ZPL data for these labels into theprinters transmit buffer. The data is then fed back into the printer by theloopback connector. A serialized number is printed on the standard head testlabel. Each label backfeeds prior to printing and feeds out to the rest positionafter printing.

FEED Key Self-Test (Print Quality Tests)

This test starts with a check of the hardware handshake lines for a loop- backconnector. If a loopback connector is not present, 14 Print Quality labels areprinted. One label is printed for each darkness setting, at the slowest and fastestprint speeds. The darkness starts at three settings below the currently configuredvalue and continues to increase until it is three settings darker than theconfiguration value. The relative darkness and speed are printed on each label.The bar codes on these labels can then be ANSI-graded to check print quality.This test can be performed without a loopback connector.If a loopback connector is detected, the following set of formats print with apause after each format (refer to page 3-9 for more information on loopbackconnectors):1)2)3)4)5)6)7)8)9)10)11)12)13)14)

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CANCEL Key Self-Test (Printer Configuration)

The CANCEL Key self-test prints a Configuration Label. This label shows theactive printer configuration, information about options and the software versionnumber. A copyright notice also prints on this label.When a single label is not long enough, the configuration information printsover several labels.

Automatically Executed Format

The printer is ready to print label formats once the Power ON Self Test andMedia Registration are finished. The first labels printed are the self- test labelspreviously described. Once the self-test labels are printed, a check is made inthe optional memory card and then the optional EPROM for a stored formatnamed AUTOEXEC.ZPL. The first AUTOEXEC.ZPL format encountered isrecalled and printed.

Printer ReadyOnce the automatic format, AUTOEXEC.ZPL, has printed, the printer enters anidle state. The printer waits for operator interaction or ZPL input to determineits next operation. While in this idle state the printer continuously checks forerror conditions (head open, head over-temperature, head under-temperature,ribbon out, or media out) in addition to ZPL input and Front Panel Key closures.The printer is capable of handling data communications, operator interactions,printing and formatting all at the same time. These are all basically independentprocesses which are performed simultaneously by the printer.In the following paragraphs, when there are interactions between processes,these interactions are described in detail. Otherwise, each operation functionsindependently, so it is described separately.

Operator InterfacesThe Front Panel Keys, LCD and LEDs are the interfaces to the operator. TheLEDs provide a very quick overview of the printers current status, while theLCD provides more detailed feedback about the printer. The keyboard supportsfeatures such as Pause, Feed and Cancel independent of the LCD. The otherkeys, along with the LCD display, allow the operator to configure the printer.

Front Panel Keys

The operator has complete control over the printer with the front panel keys.The black keys, along with the LCD, are used to configure the printer. Refer tothe XiII printers users guide for further details.

Liquid Crystal Display

The LCD display shows several types of information. The display starts with theprinter ready message shown below. For each format printed, it displays theprinting message with a label counter, as shown below.The LCD also indicates error conditions when they occur and allows the printerto be configured. The message priority for the LCD display is therefore,configuration messages first, then error messages, printing messages, and finallythe idle message.

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IDLE Message

PRINTER READY1024K Vx.x.x

PRINTING Message

PRINTING 000001OF 999999

ERROR MessagesThe error message display cycles through each of the error conditions that haveoccurred since the first error condition was detected. It also shows the printing# of # display. When an error condition is corrected, the top line of that errordisplay indicates ERROR CLEARED. Once all of the errors have beencleared, the display indicates PRINTER IDLE. The pause key may be pressedto resume printing. The possible error conditions are:

ERROR CONDITIONPAPER OUT

ERROR CONDITIONHEAD ELEMENT BAD

ERROR CONDITIONHEAD OPEN

ERROR CONDITIONCUTTER JAMMED

Warning MessagesThe Head Overtemp warning will cause printing to stop. The printer willresume printing after the head cools unless another error has also occurred.The Ribbon In/Out Warnings will cause printing to stop until the condition iscorrected and the PAUSE Key is pressed. The Head Undertemp condition doesnot stop printing.WARNINGHEAD OVERTEMP

WARNINGHEAD UNDERTEMP

WARNINGRIBBON IN/OUT

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Out Of Memory Messages

The OUT OF MEMORY conditions require the operator to press the PAUSE Keyto clear the error condition and continue operation.

OUT OF MEMORYCREATING BITMAP

OUT OF MEMORYSTORING BITMAP

OUT OF MEMORYBUILDING FORMAT

OUT OF MEMORYSTORING FORMAT

OUT OF MEMORYSTORING GRAPHIC

OUT OF MEMORYSTORING FONT

Front Panel LEDs

LEDs on the front panel are a quick indication of the printers status. Wheneveran LED should be ON and Flashing at the same time, the LED will Flash. Referto the XiII Printers users guide for further details.

CommunicationsA separate process handles the data communications with the host system, aswell as other printers and devices connected to a secondary port. This processdetermines whether the received data should be transmitted by the secondaryport, or discarded as invalid before adding it to the label generators inputbuffer. Any data received by the secondary port is automatically re-transmittedby the host port. All data transfers follow the selected hardware and softwareprotocols. However, data received by the printer is not checked for parity,framing, or overrun errors except when the printer is in the communicationsdiagnostic mode.

Host PortThe main serial port is normally the primary port. The parallel port or any ofthe optional ports may be selected as the primary port. The primary port is theinterface to the host system. It receives ZPL (or ZPL II) commands from thehost and, with the exception of the parallel port, transmits information back tothe host.

Port ConfigurationThe host port is specified during the printer configuration process. Any of theports will function as the host port.

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Serial port settings for baud rate, data bits, stop bits, flow control, and parity arealso configured from the LCD menu. The host port is configured with the sameport settings. The printer supports three software protocols for the serial port:ZebraNet, Ack/Nak, and Zebra Packet.

ZebraNet ProtocolZebraNet protocol connects Zebra printers together in an ethernet arrangement.Label formats can be sent to only one or a multiple number of printers at thesame time through the use of a Network ID code which is unique to each printer.The Network ID is configured via the LCD Menu or by a ZPL command.Whenever the proper ID number follows a connect command, the printerprocesses the data received.Additional information about ZebraNet operation may be found in the XiIIprinters users guides.

Zebra Packet Protocol

The main serial port supports a packet protocol. The packet is received andchecked for accuracy prior to processing by the printer. If the packet is receivedcorrectly, an acknowledge packet is returned to the host. If an error occurs whilereceiving the packet, a negative acknowledge packet may be sent to the host orno response at all. Once a packet is received and verified, the data in the packetis processed normally.A complete explanation of the Packet protocol is found in the ZPL IIProgramming Guide.

Ack/Nak Packet Protocol

Another version of Zebra packet protocol is supported to maintain compatibilitywith earlier printer models. Since this is not a reliable packet protocol, the Zebraprotocol should be implemented in its place where possible.

Errors ConditionsThe packet protocol responds with a negative acknowledge packet when an erroris detected. This is the only communications method that attempts to correctdetected errors. Standard communications errors, such as parity and overrunerrors, should cause packets to be invalid.

Normal ModeDuring normal printer operations, framing, overrun, and parity errors areignored. The printer attempts to print labels from the data values it receives. Theprinter always transmits data with the specified parity, data bits, and stop bits.The printer may print labels even when it is improperly configured. If the host isnot receiving responses, it may be due to an incorrect setting.

Diagnostic ModeThis mode is very beneficial as a troubleshooting aid. Each character received isprinted as a hex value. Its ASCII interpretation is printed directly above the hexvalue. Any framing, overrun or parity errors are indicated just below the hexvalue if the character was incorrectly received.

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Flow ControlThe printer will accept data and place it into the label generators input bufferuntil the buffer is full. Then the printer will only process commands that can behandled in the communications process. All other data is ignored. When thelabel generators 5000 character input buffer only has enough room for another256 characters, a signal is sent to the host to stop the data transmission. This isdone by either hardware (DTR/DSR) or software (Xon/Xoff) flow control asselected from the LCD menu. The label generator will remove data from itsinput buffer as it is processed. Once the buffer has room for another 512characters, the printer will signal the host to resume sending data. Thisguarantees that valid data will never be ignored.Data transmissions from the printer are controlled in the same manner. When theprinter receives a signal to stop sending data, it starts collecting data internally.Once the signal to resume data transmission is received, the printer will resumetransmitting data. If the printer needs to transmit data and its internal transmitbuffer is full, the printer will drop the data rather than wait for the buffer toempty.The flow control for the secondary port is handled in the same manneras the host port described above. The secondary port has its own set ofreceive and transmit buffers. The data received by the secondary port is alwaysretransmitted by the primary port.

The Command Processor

The data received by the primary port is processed in several steps. The firststep is to remove all CR, LF, NULL, XON, and XOFF characters from the datastream. The next step is to convert all command (tilde), format (caret), anddelimiter (comma) prefixes to DLE, RS and US characters respectively. The SI,STX and ETX characters are also expanded into a field separator command, astart of format command and an end of format command, respectively. Thecommand is then either processed or placed in the label generators input buffer.There are three types of commands in ZPL. Immediate commands start with a DLE character. These commands areprocessed as soon as they are received.

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All other commands are placed directly into the label generators inputbuffer.Format commands start with an RS character. These commands are onlyrecognized when they are placed between the start of format and the endof format commands.The third type of command starts with either a DLE or an RS character.These commands need not be a part of a format, but are processed by thelabel generator, along with the format commands, in the order received.

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Label GeneratorThe label generator interprets the data found in its input buffer and either storesit for later recall, or generates a set of label images from it. The memoryrequired to store the data and label images comes from a memory pool managedby the label generator. Once a label image is created, it is queued for printing.Since a single format can create several different labels, this process alsomodifies the initial image to create the other label images needed.Creating a label image from the data in the input buffer is a two step process.First the data must be processed for commands and the parameters associatedwith them. The second step is to create a dot pattern from these commands.

Processing and Formatting

Standard ZPL processes all of the commands in a format before it starts to createthe dot pattern. Since data is placed into the input buffer as it is received by thecommunications process there may be times when the label generator is waitingfor more input data.ZPL II decodes all of the commands for a single area (or field) and thengenerates the dot pattern for just that area. This allows the label generator to fillthe idle time when it would be waiting for the communications process. ZPL IIalso supports a command that allows the label generator to queue a portion ofthe label image so the printing process may start earlier.The input data is decoded to determine what data is valid and where to store theinformation. The parser receives two types of commands. Format commands aredecoded to create label images, while control commands perform some otherfunction such as storing data as a graphic image or a font.

Line Printer Mode

When in line printer mode, any data that is received prior to the start offormat command is formatted and printed (except control commands). Thenumber of characters per line and the orientation of the text are all controlled bya ZPL command. The default line printer mode is OFF, and it must be activatedto make text print. When line printer mode is disabled, the printer will ignoredata prior to the start-of-format command, except for control commands.

Control CommandsA Control command may be received at any time. It may be between formats orduring a format. The Control command will end the current Format commandbut has no other affect on the format. Control commands may perform one ofseveral functions (i.e. storing or deleting graphics, fonts or formats, or printinginformational labels).

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Format CommandsAll Format commands in ZPL have a default value for each parameter. Thesevalues are related to either the overall format or a field within the format. Theinput data is searched until a start-of-format command is found. It then copiesthe default format and field definitions to the current format and fielddefinitions. As each command is decoded, the current format and fielddefinitions are updated accordingly. Any ZPL command that affects both thecurrent field or format and all future fields or formats updates both the currentdefinition and the proper default definition.Each Field Separator command ends the current field and starts the next. Instandard ZPL mode, the current field is saved in a list of field definitions. InZPL II mode, all fields are formatted as soon as possible. The only fielddefinitions not formatted are fields with a field number and without field data. Afield definition that has a field number, serialized field data, or is a variablefield, must be saved for later reference. Since all fields with field numbers aresaved, the field will be formatted the first time the same field number appearswith field data. After saving and possibly formatting the current field, thecurrent field definition is reset with the default field values. Commands are thendecoded for the next field.Since some commands can affect the entire label, it is VERY important withZPL II that these commands are specified first. While the order is less critical instandard ZPL, these commands have traditionally been at the start of a format.Command decoding continues to update the format and field definitions until theend-of-format command is decoded. This command causes the current fielddefinition to be processed as described above. In standard ZPL mode, all of thefields that have been defined are now formatted one at a time. In ZPL II mode,the formatting has already been completed and the images are ready to bequeued for printing. The first label image is queued once for each label to beprinted from that image. The label generator then determines if additional labelimages are required. These additional images are created one at a time, byerasing old field data values and replacing them with new data values. The newimage is then queued as many times as required. This process is repeated for allof the label images that are printed by the current format.Once the labels are all queued, the current image is either partially or fullyerased for the next format. If a field was defined as a host verify field, the labelgenerator will wait for the label image to be printed before continuing. Once theimage is printed, the label generator returns the field header data and the fielddata value to the host through the communications process. The parser is nowready to start searching for the next start-of-format command.

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Memory ManagerThe label generator has several memory areas available. A font ROM, RAMspace, an optional ROM area, and optional memory card are available for storedinformation. The memory manager determines when these memory areas areavailable and what type of memory is available in each area. The ROM area andread-only memory cards must be pre-programmed. The format of thepre-programmed data is determined by Zebras PC based tools for generatingthese ROMs and cards.Data may be stored in all of these devices. Since it is possible to have the samename for data stored in several different devices, each device has a unique name.When the device name is not specified, the memory manager searches eachdevice for the data item, in the following order:RAM SpaceMemory CardOptional ROMsFont ROMThis same search order is followed at power-up for the AUTOEXEC.ZPL labelformat and for automatically installed fonts. Fonts are automatically installedwhen they have a single character name. A font, such as D.FNT, could exist inthe memory card, the option ROMs and in Zebras font ROM. Since the memorycard has the highest priority, this is the font that is installed for the ADcommand. The AUTOEXEC.ZPL format may override this with a font aliascommand.

Font ROMThe printers standard fonts and bar codes are stored in the Font ROM space(part of the code EPROMs). This device must be present for the printer to passthe Power On Self Test. This ROM is referred to as the Z device.

Optional ROMSince the ROM space is read only memory, it must be pre-programmed withfonts, formats, or graphics. At Power On, the printer determines if the optionalROMs are installed. When present, the ROMs are referred to as the E device.

Optional Memory Card

The optional memory card may be writable or read-only memory. At Power On,the printer determines if a memory card is installed and the type of card.Read-only cards must be pre-programmed, similar to the optional ROMs. If theprinter detects a read-only card, it can not save data in the option card. If theprinter detects a writable card, the printer may save data to this card. Whenpresent, the memory card is referred to as the B device.

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Battery FailureA battery preserves the data on a writable card when the power is turned OFF. Ifa writable card is detected, and the card has invalid data, the printer will displaya Battery Dead message. The card can be re-initialized by the LCD menu or aZPL command. The LCD does provide a Battery Low warning message toalert the operator when the battery should be changed. The battery status is alsoindicated on the Configuration Label by one of the following:None............ Battery RAM

(Memory not detected)

Dead............ Battery RAM

(Memory not initialized)

Installed....... Battery RAM

(Memory and battery good)

RAMThe printers standard one megabyte of RAM space is expandable to a total ofnine megabytes. General printer operation requires 256 kilobytes of RAM. Theremainder of the memory, 768K (or 8192K from 9MB), is in a single memorypool which is allocated for the storage of label images (bitmaps), graphics,formats, and fonts. The printer creates as many bitmaps as possible from thememory pool when generating label images. Only when the entire memory poolis exhausted does the label generator wait for labels to finish printing. Whendata needs to be stored for graphics, fonts and stored formats, the memorymanager waits for enough memory to become free and then stores the data.

Memory Full Conditions

While downloading a graphic, font or stored format, the memory managerdetermines the amount of memory needed to store the data. It then waits untilenough memory is free, or until all of the bitmaps are printed. Once all of thebitmaps are printed, if there is still not enough memory to store the data, theLCD displays the message Out of Memory Saving Image, ..."Font", or..."Format". The graphic image, font or stored format is then discarded.It is possible to run out of memory when attempting to create a bitmap. If thereare other bitmaps in memory, the printer waits until the other bitmaps areprinted. Once all of the other bitmaps have been printed, if there is still notenough memory, the printer pauses and displays a message Out of MemoryCreating Label. The format is then discarded.

Print ProcessThe print process controls media motion and physical printing. It performs threedifferent tasks: printing a label from the label queue, feeding blank labels andcalibrating the media sensors. The highest priority task is media sensorcalibration, followed by feeding blank labels, and then printing labels. The printprocess never interrupts one of these tasks to start another. It simply completesthe current task and then checks for the highest priority task.

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Media CalibrationMedia calibration occurs either when the printer is paused and the CALIBRATEKey is pressed, when the printer is turned ON, and when the printhead isCLOSED. A ZPL command determines the type of calibration performed for botthe Power ON and Head Closed conditions. Media Sensor calibration may alsobe selected from the configuration menu or by a ZPL command. The calibrationalways occurs at two inches per second, the slowest speed supported. The simplest form of calibration moves the media, looking for the first webthat passes the Media Sensor. This web is then placed at the proper restposition based on the print mode. A label length calibration moves the media until two webs pass the MediaSensor to measure the label length. It then feeds the second web to the restposition. A complete calibration moves the media and monitors the Media Sensorinput to determine the voltage level associated with web only and the levelassociated with web plus media. (If no distinction can be made betweenthese two voltage level readings, the media type is set to continuous media.)After analyzing the data, two webs are fed past the Media Sensor to measurethe label length, and then the second of these webs is fed to the rest position.Prior to moving the media at all, a check is made to determine if ribbon ispresent. If ribbon is present, the printer is set to thermal transfer mode. If theribbon is not present, the printer is set to direct thermal mode. The final calibration mode is the same as the complete calibration mode withone exception. The Media Sensor values are printed on the media as a bargraph. This allows the operator to analyze the same data the calibration taskis analyzing. Corrections can be made with a ZPL command to any of thevalues set by automatic calibration. The values set by calibration are appliedto any label that is then printed. Since label images may already exist, theimages may appear to be truncated.Media calibration always functions and may clear error conditions thatprevented media movement. As long as the printhead is closed, a mediacalibration may be performed. Ribbon and paper error conditions are cleared bycalibration unless the Media Sensor never detects paper.

Print Error Conditions

There are several error conditions that affect printing. Some actually stop theprinting process completely while others are only reported to the operator orhost system. For example, a head open error condition stops all media movementwhile the head under temperature error has no effect on media movement. Someerror conditions must be corrected before the printer will feed or print labelsagain.

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Paper Out, Ribbon Out, or Head Open

A paper out, ribbon out, or head open error condition stops the printerimmediately. The label being printed when the error condition occurs is onlypartially printed. The PAUSE LED is turned ON and the printer waits for thePAUSE Key to be pressed. If all three error conditions are cleared when thePAUSE Key is pressed, the PAUSE LED turns OFF. Media registration occurs(for non-continuous media) and then the printing process resumes.Printing resumes by reprinting the label that was in process when the erroroccurred. All other printer features (e.g. communications, decoding, formatting,and cancel) function normally during the error condition and while the printer isrecovering.The feature of reprinting a label after an error condition occurs can be turned offby a ZPL command. Media registration is also controlled by a ZPL command.

Head Over Temperature

When the printhead becomes too hot (>60 C), all printing stops, the Error LEDturns ON and the LCD displays HEAD OVERTEMP. The printer will waituntil the printhead has returned to an acceptable temperature (<55 C) prior torestarting. All other printer features, including calibration, function normallywhile the printhead is over-temperature.

Head Under Temperature

A similar condition occurs when the printhead is cooler than desired (<15 C).The printer does NOT stop but the ERROR LED turns ON and the LCD displaysHEAD UNDERTEMP to indicate the error condition. All of the other featuresof the printer continue to work normally. This includes printing, which shouldheat the printhead to the desired temperature. While the Under Temperaturecondition exists, print quality will be reduced due to insufficient heating of theprint elements.

Darkness of PrintThe print process controls the amount of energy required to print each dot in thelabel. The amount of energy required depends on the setting of the DARKNESSparameter, the ZPL relative darkness setting, the current printhead temperature,the type of media (direct thermal, thermal transfer), the speed of the media, thespeed of the ribbon, the resistance of the elements of the printhead, and the dotsaround the dot being printed. These factors combine to determine the energyrequired by a printhead element to print one dot.

Printhead Element Test

Since a dot cannot be printed by a damaged printhead element, the printerperforms a periodic test of each element. This test is controlled by ZPLcommands. This test is always performed between printed labels. The printermay be configured to stop all printing when a head element failure is detected orit may only display the error and continue printing. The printhead test only teststhe elements within the print width selected from the LCD menu.

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Printing Queued Labels

Without any errors, a calibration request, or a feed request, the printer is readyto print labels. The operator interface or a ZPL command may pause the printingprocess. This keeps the print process from printing queued labels but does notstop the feed or calibration functions. Once the print process is taken out ofpause, the first label queued is printed.

Print SpeedThe media speed for the label is determine by the ^PR ZPL command. Speedsof 2 inches/sec. to 12 inches/sec. are available depending on the specific XiIIprinter under discussion.

Media TrackingAll label images are printed completely. After the entire image is printed, theprinter seeks the next web for non-continuous media. This is done by feeding upto twice the known label length while looking for a web. If no web can bedetected while feeding twice the label length, an Out of Paper error will occur.Once the web is detected, the printer feeds the web to the correct position basedon the print mode and related ZPL commands.Continuous media is assumed to have the end of the label under the printheadafter feeding the full label length.The location of the label image on the physical label stock is controlled by theLCD menu and ZPL. The LABEL TOP and LEFT SHIFT parameters move theimage up and down or left and right without affecting media position relative tothe printer.

Print ModesThe print mode determines the media motion and the rest position of the mediarelative to the printer. The print mode is selected by either a ZPL command orthe LCD menu. The Tear Off Adjust parameter of the LCD menu adjusts thefinal rest position of the media without affecting the position of the printedimage relative to the media.

Tear-Off ModeThe media is at the rest position for tear-off mode when the web is over the tearbar. To print a label, the printer backfeeds the media until the start (or bottom)of the next label is directly under the printhead. The printer then prints the entirebitmap. After the bitmap is completely printed, the printer either feeds to thetear bar, feeds until the start of the next label is under the head, or stops at thetop of the current bitmap. The final position for the label is controlled by ZPLcommands and when the next format is ready to be printed. If there is anotherlabel in the print queue, the printer feeds until the start of the next label is underthe head.

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Peel-Off ModeThe media is at the rest position for peel-off mode when the web is slightly infront of the printhead. To print a label, the printer backfeeds the media until thestart (or bottom) of the next label is directly under the printhead. The printerthen prints the entire bitmap. After the bitmap is completely printed, the printereither feeds to the take-label position or just to the top of the current bitmap.When the label is completely printed, the printer feeds the label to the take-labelposition. The label is in the take-label position when it is still held on by onlythe portion of backing material that has not crossed the tear bar. This allows thelabel to hang off of the printer. After the label is pulled free, the printerimmediately backfeeds the media to the rest position.

Rewind ModeThe media is in the rest position for rewind mode when the start of the next labelis directly under the printhead. The media never backfeeds in this mode. Theprinter prints the entire bitmap. After the bitmap is completely printed, theprinter either feeds to the rest position or to the top of the current bitmap. Thisfinal position of the label is controlled by ZPL commands.

Cutter ModeThe media is at the rest position for cutter mode when the web is slightly infront of the printhead. To print a label, the printer backfeeds the media until thestart (or bottom) of the next label is directly under the printhead. The printerthen prints the entire bitmap. After the bitmap is completely printed, the printerfeeds the label to the cut position, the rest position or just to the top of thecurrent bitmap. When the label is completely printed and a cut is required, theprinter feeds the next web (the top of the label) out into the cutter mechanism.The cutter blade is activated and the printer waits for the cutter mechanism tocomplete its cycle. After cutting, the printer immediately backfeeds the media tothe rest position. If a cut is not requested by ZPL, the printer simply feeds to therest position or to the start of the next label when another label is in the printqueue.

Test ModeThe media is at the rest position for test mode when the web is slightly in frontof the printhead. To print a label, the printer backfeeds the media until the start(or bottom) of the next label is directly under the printhead. The printer thenprints the entire bitmap. After the bitmap is completely printed, the printer feedsthe label completely out of the printer and then immediately backfeeds themedia to the rest portion.

Feed LabelsThe print process feeds a blank label whenever the operator interface or ZPLindicates a blank label has been requested. The feed occurs between labelformats or while the printer is paused. Multiple feed requests feed a single label.A second blank label may be requested once the first label feed is completed.Feed labels move the media at the slew or feed speed which is set by the secondparameter of the ^PR ZPL command. All printers support 2, 3, 4, 5, 6, 7, and8 inches/sec. printing speed. The 220XiII printer supports speeds up to 10inches/sec.The 140XiII printer supports speeds up to 12 inches/sec.

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Optimized MotionThe printer always determines the minimum motion required to perform eachtask. Blank labels always feed forward and never backfeed first. Labels withslew commands always reduce the backfeed distance by the amount of slewrequested until no backfeed is required. The printer changes print speed withoutstopping. It simply decelerates or accelerates until the new speed is reached.

ZPL Commands Supported

All ZPL and ZPL II commands are explained in full detail in the ZPL IIProgramming Guide (part # 46469L). Refer to this guide for further information.

Power-Up DiagnosticsThe Diagnostic Tests may be helpful when troubleshooting the Main LogicBoard and ancillary hardware. Individual circuits are enabled, providing theTechnician with the means of checking for proper operation.CAUTIONTHESE TESTS MAY DAMAGE THE PRINTER.Main Logic Board Diagnostic Testing set-up requirements:

To perform these tests, rotary switch (SW1) must be placed in the ZERO (0)position.Use an XiII-Series printer as a test fixture when troubleshooting a MainLogic Board.The printhead connecting cable must remain disconnected from the MainLogic Board.Both a Serial Loopback Connector and a Parallel Loopback Connector mustbe installed on the Serial and Parallel Data Connectors on the Main LogicBoard. (Refer to section 3 for information on these connectors.)

When the power is turned ON, the printer will repeatedly perform the followingseries of tests until an error is detected:LED Ripple Test - The LCD displays the phrase LED Test. Each LED isturned ON and then OFF in sequence. This test is repeated after each of theother tests. The operator must visually inspect the LED operation.Program ROM CRC Test - The LCD displays the phrase ROM Test. This isthe same test as the one performed during the Power ON Self Test. If the testfails the LCD displays the phrase FAILED and all testing stops.DRAM Test - The LCD displays the phrase DRAM Test. This is a walkingzero and walking one test (a more complete test than the Power ON Self Test).The DRAM is good when 1Mbyte passes the test. The amount of functioningmemory is displayed in the lower right hand corner of the display. This valueremains displayed throughout the testing cycle. If less than 1 Mbyte passes thetest, the LCD displays the word FAILED and all testing stops.

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Keyboard Test - The LCD displays Keyboard Test. The test looks for pressedkeys. If any key is pressed, the LCD displays FAILED-Keyname and alltesting stops.SRAM Test - The LCD displays the phrase SRAM Test. This is a walkingzero and walking one test (a more complete test than the Power-On Self Test).The SRAM is good when 128KB passes the test. If less than 128KB passes thetest, the LCD displays the word FAILED and all testing stops.Second Processor Test - After passing the SRAM Test, the SRAM is loadedwith test code for the second processor. The following eight tests are run by thesecond processor while the main processor waits.1. 2nd Processor Test - The LCD displays Processor Test. The CRC valuefor the shared SRAM space is calculated by the second processor andcompared to the expected value. The second processor is operational whenthe two CRC values match. If the test fails, the LCD displays FAILEDand all testing stops.2. E 3 Test - The LCD displays E-Cubed Test. Test patterns are written to theE 3 circuit. The E 3 circuits response is checked for proper results. If the testfails, the LCD displays FAILED and all testing stops.3. EEPROM Test - The LCD displays EEPROM Test. At the start of thistest the factory default values are written to the EEPROM. These initialvalues are then verified during the test cycle. If the test fails, the LCDdisplays FAILED and all testing stops.4. Head Sensor Test - The LCD displays Head Sensor Test. This test checksfor a head open condition. If the head is closed, the LCD displaysFAILED and all testing stops.5. Head Relay Test - The printhead power relay is opened and closed severaltimes with a very short delay between movements.6. Media Sensor Test - The LCD displays Media Sensor Test. This testchecks for a Media out condition. If media is detected, the LCD displaysFAILED and all testing stops.7. Ribbon Sensor Test - The LCD displays Ribbon Sensor Test. This testchecks for a ribbon out condition. If ribbon is detected, the LCD displaysFAILED and all testing stops.8. Step Motor Test - The LCD displays Motor Test. The step motor isdriven forward a short distance (three to four inches) then reversed for anequal distance before locking into position for the next test cycle.The second processors tests are now complete and the main processor resumescontrol of the SRAM. The second processor is placed in the reset state and waitsfor the test to be repeated before running again.Serial Port Test - The LCD displays Serial Port Test. The loopback of pin 2with pin 3, pin 6 with pin 20, pin 13 with pin 14, and pin 16 with pin 19 istested. If the test fails, the LCD displays FAILED and all testing stops.Parallel Port Test - The LCD displays Parallel Test. The Zebra parallel-portloopback connector is tested. (The loopback connector involves a small circuitboard and is manufactured by Zebra.) If the test fails, the LCD displaysFAILED and all testing stops.

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Drawings and Parts Lists

In this section...PageMechanical Parts and Assemblies ................................................8-1Parts Lists and Drawings ...............................................................8-4

220XiII FINAL ASSEMBLY (ELECTRICAL) PG-2 OF 2

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PART NUMBER011300115902252062680722930007-130007-330007-6300233003330104301053023630256-B302663029630305RM303073035330392-00430392-00630392-00830393-00630423-00330494308253082630827309093095638099M38825-138825-2

PART NUMBER40031401544024840305RM40355M4400146001-1460914610546196M462244626746302-4M46305M46444466634666446691-1M46691-2M46691-3M4680847009-147009-347009-84710147302-4M474444780848001480074802348302-4M4840448405484114844448808Q10019Q10057

AA, BB, & CC INDICATE

90XiII,140XiII & 170XiII PRINT MECHANISM ASSEMBLY PG-3 OF 3

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PART NUMBER0115902252062680722922001-122023-122099M22249222662227522302M22304M22305M22391M22444228082282530007-930009-103003330104301053023630256-B30296303073035330392-00430392-00630392-00830393-00630402-00630423-003304943082630827309093095631493M

170XiII PRINTHEAD SUPPORT ASSEMBLY

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PART NUMBER01153011590626822000M220022200322013220152201622017221742218022181-P221912260222640-02022640-02530007-830009-930314R30391-00330392-00430402-006304943078140193401944802346481-14666546882-0034818248289Q06020

MEDIA REWIND OPTION ASSEMBLY

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PART NUMBER01155016600182202133084491042122193223202238222819301333018130196-10030196-15030196-20030196-2513019830199302083021030214302153021630217-13021930236303133032030374M30380M30382RM30391-00330392-00430394-00530405-00630405-0083081630819

NOTE1. IF REWIND OPTION IS INSTALLED ON CUTTERMACHINE, BE SURE TO ORDER CUTTER/REWINDPLATE (ORDER BY MODEL'S PART NO.)2. POSITION BRUSH SO THAT APPROXIMATELY1/8" OF THE BRUSH'S BRISTLES RUB AGAINST EACHMOVING LABEL AND THE BRUSH'S BRISTLES AREPARALLEL TO THE LABEL EDGE.

NOTE: Shaded codes NOT recommended for use as a Command

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Appendices

Setting Burn Temperature For IN SPEC Bar Codes

All Direct Thermal and Thermal Transfer materials do not have the same Burn Temperaturerequirements. The best way to check for the proper Burn Temperature is to use a Bar Code Verifierthat actually measures bars/spaces and will calculate the PCS ratio. Without the assistance of averifier, your eyes and/or the scanner to be used in the system, are the best bet for picking theoptimum burn setting. What follows is a simple yet effective method for adjusting the burntemperature to print IN SPEC Bar Codes.

1.

Load media (and Ribbon if required) according to the appropriate Media

Loading and Ribbon Loading Instructions found in the printers UserGuide. Insure the Print Method is appropriately characterized for eitherDirect Thermal or Thermal Transfer.

2.

To print a label for evaluation, use the following procedure:

A. With Power OFF, depress and Hold the FEED Key.B.

Turn the Printer Power ON, then release the FEED Key.

C.

The Printer will perform the Power ON Self Test (POST),

calculate label length, and then begin printing test labels.

3.

Print a label, then depress the PAUSE Key. The label will contain twoBar Codes as well as other printer information. Normal Bar Codes areprinted in a horizontal format as they feed out of the printer. Rotated BarCodes are printed in a vertical format.

4.

Compare the test label printed, to the Bar Codes in Figure E.1. If the testlabel appears underburnedor overburned, Refer to section 4.1 andincrease or decrease the BURN TEMP Setting accordingly.

5.

Resume printing by pressing the PAUSE Key again. Print a few labels atthe new setting and verify that proper IN SPEC Bar Codes are beingprinted. Repeat steps 3, 4 and 5 until satisfied.

6.

To terminate the printing of the test labels, depress the PAUSE Key, thendepress the CANCEL Key.

Printing ConditionsOverburned - Overburned labels are fairly obvious. The normal Bar Code bars increase insize, and the openings in small alphanumeric characters may fill in with ink. It may be readablebut not IN SPEC. Rotated Bar Code bars and spaces will run together.

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Slightly Overburned - Slightly overburned labels are not as obvious. The normal BarCode will be IN SPEC. Small character alphanumerics will be bold and could be slightly filledin.The rotated Bar Code spaces are small when compared to the IN SPEC Code, possibly makingthe code unreadable.

slightly overburned for IN SPEC Bar Codes. Both normal and rotated Bar Codes will be INSPEC, but small alphanumeric characters may not be complete.

Underburned - Underburned labels are very obvious. Both normal and rotated Bar Codeshave incomplete bars and spaces. Small alphanumeric characters are unreadable.

In Spec - The IN SPEC bar code can only be confirmed by a verifier, but it should exhibitsome very visible characteristics. The normal Bar Code will have complete, even bars and clear,distinct spaces. The rotated Bar Code will also have complete bars and clear distinct spaces. Although it may not look as good as a slightly overburned Bar Code, it will be IN SPEC. In bothnormal and rotated styles, small alphanumeric characters will look complete.